Hi pgrant,

Some other things to try:
Check if your Word or Outlook is working properly in safe mode. From Start|Run, input:
winword.exe /safe
and:
outlook.exe /safe

If the problem does not occur in the safe mode, the issue might be related to a 3rd-party add-in, in which case we can try to disabling them.

Does the crash occur if Outlook is already running, or only if it's closed? If only one of these is true, a temporary workaround would be to ensure the other state applies when doing the mailmerge.

If the problem is only with email mailmerges, you could also try re-registering outlmime.dll. From Start|Run, input:
regsvr32 outlmime.dll
if successful, you should receive the following message:
DllRegisterServer in outlmime.dll succeeded.

__________________
Cheers,
Paul Edstein
[Fmr MS MVP - Word]