I've changed the topic, as this is the real problem. Advice everywhere says that Copy Local = false will prevent the DLL from inclusion in the XAP, technically this is true, but it's not that simple. I can now see that I'm having trouble because my projects are not like the childishly simple ones you see in samples and videos. Although I reckon it's still quite simple with project dependencies originally like this:
Foo.App ref -> Foo.Controls (Copy Local true) ref-> C1.Silverlight (Copy Local false) ref-> C1.Silverlight.Chart (Copy Local false) ref-> C1.Silverlight.Extended (Copy Local false) ref-> C1.Silverlight.Gauge (Copy Local false) None of the C1 DLL files appear in the Controls bin output folder, so I know Copy Local false is working in that project. However, in the App bin output I can see the Controls DLL and all four of the C1 DLLs. From there I presume they get included in the XAP. The stupid workaround is to add unneeded C1 references with Copy false to the parent App project. So the fixed solution now looks like below. Greg Foo.App ref-> C1.Silverlight (Copy Local false) ref-> C1.Silverlight.Chart (Copy Local false) ref-> C1.Silverlight.Extended (Copy Local false) ref-> C1.Silverlight.Gauge (Copy Local false) ref -> Foo.Controls (Copy Local true) ref-> C1.Silverlight (Copy Local false) ref-> C1.Silverlight.Chart (Copy Local false) ref-> C1.Silverlight.Extended (Copy Local false) ref-> C1.Silverlight.Gauge (Copy Local false)
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