This won't help the OP or others who already have CD's, but as I'm looking at my current photos online and doing edits, I noticed a possible solution.
Ive gotten the photopass CD for several trips in the past, and like the OP, I noticed that for pictures where you add a border all the way around (like the Test Track border), when you print a 4X6 of the photo, you end up losing some of the border, and it just doesnt look really good. The problem is that the edited photo is scaled to 5X7 dimensions, so if you print a 5X7 you get what you see, but you lose some with a 4X6 (which is what I print out for my albums). When you add a border or icon and save as copy, you can see that it defaults to a 5X7 print under the product type. With my photos this time, Im changing the product type to two 4x6 prints and its obvious that its saving the photo a bit differently than when its left at the default 5X7.
I havent actually tried this before because I never thought about it, but Im assuming that the print will come on the CD scaled to a 4X6 print instead of 5X7. With many of the icons/borders/signatures, it wouldnt matter if you lost a bit of the photo when you print a 4X6 (youd lose a small part along each of the long sides), but with the ones that go all the way around like Test Track and the ones with a character-type border (like Minnies polka-dots), it looks funny when you print a 4X6 and lose some of the border.
Has anyone tried this and can confirm that is you save the copy as 4X6, it actually comes scaled to 4X6 on the CD? I can certainly report back after I get my CD, but that will probably be at least a month from now.