11.03.11 01:04:13 tool pc 01.00.00.0609 ----------------------------------------------
11.03.11 01:04:13 reference function: _write_to_error_file
11.03.11 01:04:13 reference address: 42ca20
11.03.11 01:04:13 No More Errors For Tools By: {TLS}Udie
11.03.11 01:04:13 EAX: 0x00000000
11.03.11 01:04:13 EBX: 0x00000001
11.03.11 01:04:13 ECX: 0x00000000
11.03.11 01:04:13 EDX: 0x00000000
11.03.11 01:04:13 EDI: 0x0018F268
11.03.11 01:04:13 ESI: 0x00000000
11.03.11 01:04:13 EBP: 0x0018F140
11.03.11 01:04:13 ESP: 0x0018F130
11.03.11 01:04:13 EIP: 0x77AB0BD2, 83 C4 04 C2 ?????
11.03.11 01:04:13 EXCEPTION halt in \halopc\haloce\source\memory\array.c,#130: index>=0 && index<array->count

Try using the default tool that came with HCE, then post the results.
"heh, it was actually caused by having 2 sided faces, and then having % applied to those materials that were double faced. it was becuase i ripped the bsp from b40. so in essence, it was actually creating 4 rendered face's on one triangle and screaming when doing collision
" that's the solution that Higuy found when he got this error.
You could try making the directory to the item shorter, too. (removing some unnecessary folders)

Thank you.