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I'm on XP and java 1.6

I have no idea what can cause that. I don't see it on my PC.
What versions of OS, JDK, IDE are you using?

Have you looked at the code that draws the lines that are the problem?
What variables controls where the lines are drawn?
How do those variables get their values?

Where are the lines begin drawn? What variables control where the lines are drawn?

Are you talking about where the fillRect methods puts the colors?
Look at the parameters passed to those methods to see why they aren't what they should be.

Can you explain what the difference is between those two images?
One thing I noticed: you call setVisible BEFORE you are finished getting all of the GUI ready to be viewed. Do setVisible after...

The value of i=10 is past the end of the array. The valid indexes are 0-9.
Check your logic to see how i can be > 9

Your print out does not show anything useful to help find the problem.

What are the values of i and j and currentRow when the OOBE occurs?

What are the values of i and j and currentRow when the OOBE occurs?
What are the dimensions of the guesses array?

I don't know where line 77 is so I can't suggest any fixes.
What values printed out when you added the println to show the value of the indexes being used on that line?
The basic fix is to check...

Look at the code at line 77 and see how the index can be past the end of the array.
Add a println before line 77 to show the value of the index if you don't see how it can be OOB.