Thanks, Ludek. Too bad a couple hundred dollars for an upgrade isn't an option.
Tried the "No Printer" idea on the fairly simple report I've been testing. I was hopeful, since it was set to use a network printer on a server that was decommissioned years ago. The file was last saved 5/25/2005 and asked if it is okay to update to the newer format, which I okayed. Alas, no luck; it still hangs on the second call.
I'm not clear on the role of the printer definition in the .rpt file. I've been distributing that .rpt to the client for runtime use for years. They have a completely different network environment from mine with different printers defined, and the unmatched printer definition has not been a problem. My goal, which otherwise seems to work, is for the .rpt file to be purely for formatting, with data and printer definitions provided externally.
I will have to come back to your other suggestion of creating a test app in a few weeks. The client only authorizes so many hours per month 
.
Thanks for your help,
Mark Berry
MCB Systems