Hi aovc,
Word's spell-checker is running because the mailmerge output's spelling hasn't been checked. You could over come that by setting the mailmerge main document's text to 'no proofing'. After all, there shouldn't be any typos remaining by the time you execute the mailmerge. That should carry through to the output document.
I'd also suggest breaking the mailmerges into sets of 100 records or so. That way, the performace for each document will be better.
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Cheers,
Paul Edstein
[Fmr MS MVP - Word]
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