Hi All,
Having just got DR to work in viz2005 I thought that i’d summarise what was needed for me to get it working:
Firstly, make sure the VIZ 2005 directory is not set to read only 
1. create a file called vrayspawner.ini in your viz root directory. Edit with notepad and put this info inside:
TempDir=C:\Program Files\Autodesk VIZ 2005\network
AppName=C:\program files\Autodesk VIZ 2005\3dsviz.exe
make sure this file is saves with the ini extension (not txt). Right click on start, click explore, go to tools → folder options → View, then untick “Hide extensions for known file types”. Now you should be able to rename the txt file to an ini
Also, adjust the locations this file points to according to what is needed. For example, some people use a network drive for the TempDir emp
The reason for the ini file is because by dafault (no ini), the program looks for 3dsmax.exe rather than 3dsviz.exe
2. Find any completed job .xml file from the backburner 2 directory and copy this into your viz root folder, then rename this to vraydummy60.xml
3. Open viz 2005 and save a new job over the file vraydummy60.max in the viz root directory. You may need to insert a camera before saving called cam_0 (depends on contents of your vraydummy60.xml file)
4. double click on vrayspawner60.exe in your viz root directory. This should start vraydummy, and the vray spawner.
Notes: if vray spawner or viz dissapear straight away, open and study these two files for indications of why there was a failure:
c:\VRSpawner.log <---the location of this file may vary
c:\program files\Autodesk VIZ 2005\network\ToServer.txt <---if viz keeps opening and closing, look in this file and see what the error is (be quick though as the file dissapears after a retry)
Lastly, delete contents of c:\program files\Autodesk VIZ 2005\network as another thing to try if all else fails.
Hope this summary of my day helps someone else 
BTW: I doubt many people would get all of this to work easily without help so I think for vray 1.5, if the whole process was made much easier then more people would have luck using DR with viz2005