Went back and loaded the autobuild - no problems creating the badpixel file.
Interesting. Can you report the free memory value shown by "Miscellaneious->Show Memory Info" for both builds.
Loaded the new test version again - can't build the badpixel file. The script itself seems to behave differently (erroneously)
Are you running a script, or using the built in badpixel.bin creation option in the raw menu? The script is obsolete and should not be used.
What is the output when you try to create badpixel.bin? If it disappears too quickly, you can see it in
"Miscellaneous->Console->Display last console"
When it succeeds, it should show the number of badpixels. It would be helpful to know that, as well as the output in the case it doesn't work.