That (not unusual in this case) is odd. I created the merge document from scratch and used only those fields that were available to me in the dropdown from the datasource. The mailmerge works flawlessly when done manually.

My data holds different flavours of data, each one with a different report. ie DR has one, DT has one, FR etc. We've been trying to create a record for DR RPL. Maybe I will try a FR RPL (different report, different SQL) and see if I get similar problems. That may help isolate the merge document as the culprit.

I'll report back. In the meantime, with my other post begging for help, I will send you the data source. Perhaps with that something unusual will jump out.

Thanks Paul.