Hello Matt Walters,
Unfortunately we are unable to reproduce the problem with last release Q3.1421 and with latest release R1.502 as well as with latest source code. What we did is exactly what you described - created a static test list, added 2 tests, set RecycleBrowser to True, run test list - it runs in 1 browser. Then added a third test and run the test list - all 3 tests run in the same browser.
In order to follow on the problem we will need more details about your setup and tests.
Which version of Telerik Test Studio are you using - is it the old Q3 release or the latest R1 release? Can you confirm the problem exists with latest release also?
What type of tests are you executing - are they html or Silverlight? Can you provide a set of tests or a project that illustrates the problem? Do you have coded steps inside your tests? Can it be by chance in some coded you initialize the browser again? Any additional information will be helpful to track down the issue.
the Telerik team
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