Maybe it is triggered by some setting(s) in the CHDK configuration. Does anybody remember what settings you changed from the defaults?
all the testing i have been doing is with stock chdk, no changes
969 -no settings transfered from anywhere, always a fresh formats on the card - NO crashes
972 - same as above - but crashes
1001 and above - crashes...
but on a single 4GB fat16 partition - always perfect - no crashes ever on any build.
i've tried a 2mb and 16mb boot partitions - maybe i need a bigger boot partition???
will try getting the romlog thing - will use build 1050 to test and get romlog.