[color:"orange"]to fix this, all i need to do is copy dgen_themes.000 that is 2.5mb over the 1.5mb[/color]

My dgen_themes.000 file matches both the sizes and CRC32 values of yours, from before and after the game is started, and I have not had any problems. Perhaps when the Larians get back on monday they can try to figure out why that change would cause a crash in your case.