Even, with only dumping string builder at that level, it fails on memory. Is there a way to negotiate directly with the string builder instead of using its .ToString() method?

        ' Create a file by passing an encoding
        ' expO1 String builder
        ' expC1 File
        ' expC2 Encoding
        ' expL1 If we log the error if the file cannot be deleted
        Public Function CreateFileEncoding(ByVal toStringBuilder As StringBuilder, ByVal tcFile As String, _
         ByVal tcEncoding As System.Text.Encoding, ByVal tlLogError As Boolean) As Boolean
            Dim llSuccess As Boolean = False
            Dim lnCounter As Integer = 0
            Dim lnDelay As Integer = 250
            Dim lnRetry As Integer = 8
            Dim loFileStream As FileStream
            Dim loStreamWriter As IO.StreamWriter

            For lnCounter = 1 To lnRetry

                Try
                    loFileStream = New FileStream(tcFile, FileMode.Create)
                    loStreamWriter = New StreamWriter(loFileStream, tcEncoding)
                    loStreamWriter.Write(toStringBuilder.ToString)
                    loStreamWriter.Close()
                    loFileStream.Close()
                    llSuccess = True
                    Exit For

                Catch loError As Exception

                    ' If we have not reached the maximum tries of 8, we retry
                    If lnCounter < 8 Then

                        ' Wait for a timeout before retrying
                        System.Threading.Thread.Sleep(lnDelay)

                        Continue For
                    End If

                    ' If we log the error
                    If tlLogError Then

                        ' Get the proper definition as per the current scope
                        If oProcess Is Nothing Then
                            oApp.ErrorSetup(loError)
                        Else
                            oProcess.ErrorSetup(loError)
                        End If

                    End If

                End Try

            Next

            Return llSuccess
        End Function