It seems as though your application is opening the RTF, creating a temporary copy, then using that as the mailmerge data source. Since these RTF files (and their temporary offshoots) are being used as the mailmerge data source, I have to wonder why you're using that format rather than a plain CSV format. I suspect you'd have less trouble with the latter.

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Cheers,
Paul Edstein
[Fmr MS MVP - Word]