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That'll teach you to use a build expression and a table with merged cells in the right hand column!
If those statements are true, see Snippets on my site.
I don't think that's it. As a test, I removed all the pages in my TOC and added a fresh page with just the word "test" typed on it and it still crashes.
Uhhh, do you think a .CHM only contains pages you see in the TOC? If so, you are ever so sadly mistaken. There may be tons of topics inside your .CHM file that never see the light of day in a TOC.
Try this. Create a totally new project containing only a single page. Compile and see if it crashes. Then begin importing pages from the errant project a few at a time. Compile. When you reach the point where things crash, you have narrowed down the culprit.
Compile without a build expression. Does it still crash?
If it does, create a new project and put in a table. In the right hand column merge two cells. Tag any one of the topics. Create a build expression and apply it when you build. Does that crash.
If the first answer is No and the second is Yes, my theory is proved. Then see Snippets for the answer. Otherwise follow Rick's test to find what else is causing it.