anyway, what eventually worked for me was to go back into my VS 2005 dev machine and create a web set up project. go into the project properties and click the prerequisites button, select CR for .Net 2.0 and then just build the empty setup project. if you look in your output folder, there is an installation file called CRRedist2005_x86.msi. Just whack this onto the server and your crystal reports should run fine, i didn't need to reboot or restart IIS. Note there is no also need to copy any of the CR dlls to your web site bin folder.
