Deploying crystal reports 8.5 - error in exporting to RTF & PDF

Question

Hi guys. I'm at my wits end, trying to get a valid build of a legacy app running reports under Crystal 8.5 going.
I've scoured google for days, and I've tried almost everything people have suggested. At the moment I've got the installer working, it installs and registers all the crystal dll's that everyone says are needed. However, when I try and and export a report to RTF or PDF (other options like excel work fine), it simply dies, doing basically nothing. The save to disk dialog just closes and nothing happens. If I rename or delete crxf_rtf.dll, the program will crash or hang, indicating that this is the file responsible for exporting to rtf.
However, the only machine in our office that this will work on is one with a C:\Program Files\Seagate Software\crtslv.dll file.. Same kind of test indicates that on this machine, the above file is being used for exporting. So, where am I going wrong? It seems ludicrously difficult to find a straight, no-nonsense guide on how to deploy crystal reports 8.5; the official documentation doesn't even mention it! What is the easiest way to do this?
I have tried several third-party options ( http://www.fryan0911.com/2008/09/crystal-report-85-runtime-files.html ) like these..
Any ideas?
Ok so here's a further breakdown with some more information; hoping it might help someone to come up with an answer...
If I install a crystal "distributable", like the one linked above, and then install my project (with all crystal stuff turned off in the installer), everything works perfectly apart from exporting reports to rtf.
If I make my own installer, following the Runtime.hlp and the crpe32.dep, and put all dll's in the windows/system32 folder (apart from two, can't remember their names), I get two different errors, depending on the version of crpe32.dll I use.
One gives me "Error 20599: Cannot connect to SQL Server", whenever I try and run a report.
The other gives me "Error 20000: N", whenever I try and run a report.
Anything sound familiar here guys? I have dll dependency headache.
Again, more info - I just checked out the PC's already in deployment (we had to re-do in the installer for some changes, the guys who did it originally aren't around anymore), and here is a list of the dll's installed on the machine.. what deployment method would this point to?  And how can I replicate it?  I'm not sure if I grabbed all the required DLL's from the client machine, as it didn't seem to follow the Crystal 8.5 deployment instructions, I could have easily have missed some? So I can't just use what I've got to create an installer and hope that it works...
"C:\Windows\Crystal\P2LIFMX.dll"
"C:\Windows\Crystal\p2lora7.dll"
"C:\Windows\Crystal\P2lsql.dll"
"C:\Windows\Crystal\P2lsyb10.dll"
"C:\Windows\Crystal\p2sacl.dll"
"C:\Windows\Crystal\p2sexsr.dll"
"C:\Windows\Crystal\p2sfs.dll"
"C:\Windows\Crystal\p2sifmx.dll"
"C:\Windows\Crystal\p2smapi.dll"
"C:\Windows\Crystal\p2sNote.dll"
"C:\Windows\Crystal\p2sora7.dll"
"C:\Windows\Crystal\p2soutlk.dll"
"C:\Windows\Crystal\p2srepl.dll"
"C:\Windows\Crystal\p2ssql.dll"
"C:\Windows\Crystal\p2ssyb10.dll"
"C:\Windows\Crystal\p2strack.dll"
"C:\Windows\Crystal\p2bbde.dll"
"C:\Windows\Crystal\p2bxbse.dll"
"C:\Windows\Crystal\P2ldb2.dll"
"C:\Windows\System32\crviewer.dll"
"C:\Windows\System32\crxlat32.dll"
"C:\Windows\System32\CRXML15.DLL"
"C:\Windows\System32\CRXML15R.DLL"
"C:\Windows\System32\CRXML15S.DLL"
"C:\Windows\System32\CRxmlx07.dll"
"C:\Windows\System32\CRxmlx07r.dll"
"C:\Windows\System32\crypt32.dll"
"C:\Windows\System32\cryptdlg.dll"
"C:\Windows\System32\cryptdll.dll"
"C:\Windows\System32\cryptext.dll"
"C:\Windows\System32\cryptnet.dll"
"C:\Windows\System32\cryptsvc.dll"
"C:\Windows\System32\cryptui.dll"
"C:\Windows\System32\Crystl32.OCX"
"C:\Windows\System32\cscdll.dll"
"C:\Windows\System32\cpeaut32.dll"
"C:\Windows\System32\craxdrt.dll"
"C:\Windows\System32\Crbas14.dll"
"C:\Windows\System32\CRBAS15.DLL"
"C:\Windows\System32\CRBAS15R.DLL"
"C:\Windows\System32\Crdb214.dll"
"C:\Windows\System32\credssp.dll"
"C:\Windows\System32\credui.dll"
"C:\Windows\System32\Crgup14.dll"
"C:\Windows\System32\CRiadx07.dll"
"C:\Windows\System32\CRiadx07r.dll"
"C:\Windows\System32\Crinf14.dll"
"C:\Windows\System32\Crinf914.dll"
"C:\Windows\System32\Cror714.dll"
"C:\Windows\System32\Cror814.dll"
"C:\Windows\System32\crpaig32.dll"
"C:\Windows\System32\Crpaig80.dll"
"C:\Windows\System32\crpe32.dll"
"C:\Windows\System32\Crsyb14.dll"
"C:\Windows\System32\crtdll.dll"
"C:\Windows\System32\Crutl14.dll"
"C:\Windows\System32\CRUTL15.DLL"
"C:\Windows\System32\CRUTL15R.DLL"

Answer 1

Wow. I've never seen an app load all 3 SDKs in one go. the RDC, Automation Server, OCS and print engine APIs all in one (?!)Who wrote this app?
Don't know - the app was written years ago.. It's all a bit messed up, i'm just the cleaner :S
Once again, I have not a clue as to what SDK you are using.
What Sp1, SP2, SP3? Do you have links to these?
By SP3, I meant Windows XP Service Pack  3, 2, 1 - I've read around the net that Crystal 8.5 exporting breaks when you install sp3, and I thought that perhaps my deployments were failing because they were compiled on a sp3 box?
There is also CR 8.5 Service Pack 3 - apparently it can make CR work on Vista/Win7?
http://resources.businessobjects.com/support/additional_downloads/service_packs/crystal_reports_en.asp
I have tried installing on dev machine, recompiling installer and running on test box - doesn't seem to help..
Do you have any machine where this actually works?
Yep, it's working on the clients machine - that is the one suffixed as "AA" in the linked difference file above
1st place to start is with a working app - is there such a thing? ^^
Next you want to know what SDK you are using.
Ok, so the VB6 app, under Project > References, lists : cpeaut32.dll
under Project > Components, lists: Crystl32.ocx
Is that any help?
Then you want to know what dlls to deploy.
Knowing the database connection type is good.  - ODBC
Knowing the version of the db client that works is good. But that depends on having an actual working app.
Do you have CR 8.5 designer and are you able to run and refresh the report there? 
Yep, I have 8.5 designer, and I can run and export the report fine.. But when I run MODULES on it, it's referencing C:\Program Files\Seagate Software\Shared\ExportModeller.dll & crtslv.dll..  Which don't exist on the client machine at this point in time..
I'd recommend you stop doing what ever you are doing, answer the questions and wait until I get back. As it is, you're all over the place and by the time I have a chance to reply, you're 1000 miles out in the bushes on your own. So, please answer the questions above and wait...