If you need another pair of eyes, tell me what tests you want to run, I have a couple of cameras to test on, and have been watching the hunt for the cause of this problem for a while.
If you want to, any more data we can get on which cameras are affected would certainly be helpful. However, if you have better things to do with your cameras, I wouldn't say this is urgent.
If you have ptp setup, the message test is easy and doesn't put wear and tear on the camera
get the latest chdkptp lua files from svn
https://www.assembla.com/spaces/chdkptp/trac_subversion_toolstart chdkptp -i -c
run the commands
!m=require'extras/msgtest'
!m.load()
set cli_time=true
!m.test(100,100000)
The 100000 is how many times you want it to run. It looks like 100k isn't really enough to trigger it reliably, 1 million (should be ~ 5 hours on digic IV) might be a decent sample.
If you hit the bug on a stock build (without my debug patch from this post
http://chdk.setepontos.com/index.php?topic=8273.140), it will should start spamming "send failed" instead of ok. On the debug patch, the "b" count in misc debug vals will go up, and resN.dmp files will be written each time it's hit.
Alternatively, you can use the script posted here:
http://chdk.setepontos.com/index.php?topic=8273.msg100018#msg100018with the settings posted here:
http://chdk.setepontos.com/index.php?topic=8273.msg100090#msg100090Or you can roll your own script to try to trigger it. We know the bug happens in resume, so aside from whatever other unknown factors are involved, more frequent sleeps should trigger it more. I have a gut feeling that the camera being "busy" is a factor, but that could easily be wrong.
One experiment I've had in mind is a script that
press half shoot
sleep(10) until get_shooting
record time it took for get_shooting to go true
release shoot_half
sleep(10) for the same amount of time as it took get_shooting
With decent statistics, this could tell us if being in half shoot is required or more likely to trigger the bug. This would require the above mentioned debug patch to keep running when the error happens.