I thought (wrongly) if I created a new instance of Excel it might
work, but yes I did have to kill it a couple times.

Both of your solutions work, but the copy/paste is a bit more
complicated than ws.Range("B3").Copy xlSheet.Range("A1"), I just used
that to keep it simple. So it looks like I'll just have to add a new
tab to the ActiveWorkbook first, then copy that to a new wb.

Thanks for all the help guys.

-- Dan