Thanks, that very much like what I was looking for, and something to point me in the right direction. Done tons of coding from vb, but never in vba.

Of course this morning I found out that the header string is limited to 256 characters so I spent most of the day changing everything to DocVariables. But this should work just fine with DocVars instead of merge fields with just a bit of tweaking.

DocVars will work fine, because we are just creating 1 letter at a time, and we aren't producing junk mail, etc.