Born2Bongo - Your response is dead on. I have a blank template called template.xls with the column headers in place (no data). The output is know as report.xls (based on template.xls but with all of the data). I basically do the following:

1. Delete the existing report.xls (from the last time the SSIS package ran).

2. Copy the template.xls to the old location that report.xls was at.

3. Rename template.xls to report.xls.

4. Run the process that dumps the output to report.xls.

Works great.