datareport seems to crash writing exe file

It appears as though adding a datareport
into my current project is causing the
writing of the EXE file to crash.

I have even gone as far as removing my
dsr file and adding in the default (unchanged)
datareport1.dsr file and even this causes the problem.

If there is no dsr files at all, then we are ok.
If all I want is to compile/run my project from
VB6, then its ok with the datareports.
Trouble starts when its time to make the EXE file
and I have DSR files in my project.

We get past the compiling, it starts writing
the exe and about "2/3" of the way in VB6,
crashes with an exeption fault.

FYI - The project currently has 5 BAS files
and 23 forms (frm files)
and they make an EXE file size of 648K.

Are there any known issues on this topic
that a semi newbie might need to be aware of?

thanks
Harry