Thanks for the input Old_Grey, I think I have made progress.
Many companies (not one) are complaining about the problem with the Gerber border file. So it is something in Fritzing for sure.
Here is what I have figured out:
IF I choose a different PCB (curved edge, elliptical etc) it works.
IF I choose the generic rectangle PCB it fails.
So there seems to be a problem with the rectangle PCB choice at the end of the day.