Worked out my problem!! I'm guessing it's the same as yours too.

In ISBoxer... at the top expand repeater Profiles, you should have a Default one there. Click on it, now down the bottom, under Character Sets.... I had two character sets.. the toons on my main pc and the toons on my second computer. I removed the character set for the toons from the second computer... (so only one character set in it..) Did copy + export to all computers.. and it's all working fine now.