I have no idea why this would work in CR but not when called from VS. Have you downloaded the latest service pack for VS 2005? I have a link to it in the announcements section at the top of the posts.

I would do a little more debugging to figure out if the communication between VS and CR is 100% accurate. Try printing the string from VS in the header to make sure it didn't get truncated and that all the characters came through properly. Secondly, try modifying the formulas the move the columns and have them return the 'before' and 'after' positions of a couple columns. Make sure the calculation is still working fine. If all that checks out and you didn't discover what piece was missing, then I guess it's a bug with CR.  Oh yeah - you don't have the report saving the data do you? that might keep it from refreshing everything properly.

Wait.... I just saw that you have references for CR 10.2 and 11. 5. What's up with multiple versions in your project??? That's probably a big problem. You need to delete all references to 10.2 and just use the 11.5 libraries. Mixing and matching libraries is a very bad thing. When you do an upgrade of a project, make sure there are any unwanted libraries hanging around.