Are there any dependent components used by this ActiveX EXE component that may not be registered?
You mentioned using DCOM, but I'm not sure why you would need this for the ActiveX EXE since it's running on the same system as the web application. I would think that using Regsvr32 to register the ActiveX EXE would be sufficient.
Also, if the ActiveX EXE is secured for authenticated users then the web application would probably need to have impersonation enabled in order to allow authenticated users access to the component.
Paul ~~~~ Microsoft MVP (Visual Basic)