Thanks everyone for all the help. I'm going to attempt the win 7 install today and see if there is ANY difference. If it doesn't help at all, which I really don't believe it will, I'll just have to buy a new PC. I wish I could bill AC or Crystal Reports for it, but oh well.......
With a little more time dedicated to developing a COM object, you can completely remove the need for Crystal Reports; in my opinion!
Bert, it does seem hit or miss with OS. I wonder if there are any background operations on the PC's that run it fast, any third party apps (i.e. AVG), what exact win XP version they are on, sp3, media center.. etc. Intel or AMD chips? Maybe a benchmark comparison software to analyze??