Hey Peter -
thanks for trying to solve my puzzle.
Here is my crash report: http://pastebin.com/g8CSNX5x
Was on hold with Adobe support and they narrowed it down to this document, it is 25 MB.
I checked type faces and files. One questionable file is OPI.
I figured a work around for PDF -
But still need to make a SWF of this and not sure of work around there...
I think, perhaps, I check in irregularly, but still frequently :-).
The crash is in a atypical thread (not thread 0) because it is in the [background] PDF export, which takes place in a different thread.
Unfortunately it's not very enlightening.
It's in the guts of AdobeBIB, about which I have recently been advised: "Bravo Interface Binder is a low level framework developed by coretech group that handles first, low level mechanics of function calls between components and second, patterns that one component should employ when using services from another component."
Have you tried exporting to IDML and trashing your preferences?
If so, then I think the next step is Divide and Conquer.
Working with a copy of your document, delete half the pages, and see if hte problem follows. Repeat until you find the source.
Could you share a copy of your file with me?