You also need to post the library where you keep your Variables. It would be more helpful if you zipped up the contents of your project and post the zip file.
Did your executable work without the custom control, and with one of the built in data types?
Are you trying to run these executables on computers that don't have LabVIEW installed?
I am not 100% sure, but I think you will need to include the .ctl file in your build directory or even include it in the executable as one of the source files.
If you are installing the executable to a machine that does not have LabVIEW installed then you will need to create an "installer" that includes the variable engine.
Yes, I agree... building executables takes awhile to get use to and isn't very intuitive.
-Nic