I seemed to have ran into an issue with open sauce tool. It compiles .yelo maps fine and says there's free tag space but when I play the map, depending on the BSP, the game exceptions. I'm assuming it is due to tag space because removing tags from the scenario seems to fix the problem. Is there a way to fix the issue without removing tags?

Sounds more likely that the tags you removed were what caused the exception. I say that because I've not run into this issue or heard of it. What tags did you remove? Need more details to help.

At first it was the zteam battle rife which worked fine in other maps. Since then it has been cmt brutes, scenery tags even vanilla vehicle tags. It seems like I'm limited to how many I can have in the map. It seems to happen coincidentally with large bsps.

It's a known issue that has been a problem with all the maps in SPV3 based on TSCE. Unfortunately, you just need to look at ways to reduce data clutter and get it under the limit. I can't imagine why you are hitting it, the stuff in TSC:E and SPV3 combined is a hard thing to match in terms of sheer data content.

Like I said its it occurs on large BSPs. The maps can sometimes load but when switching to a large BSP the game will exception. So I stripped all unit dialogue from the map to free up tag space and nothing changed. It still exceptioned. Then I removed one biped tag and it worked. Is it possible it has something to do with model data?

you are looking at it the wrong way. Think of it as a bathtub. The tags are the water, and the BSPs are the person getting in at the time. A skinny person will fit in fine, a fat person will cause the water to be displaced and overflow. That's when your game crashes. By removing sound tags, you are essentially removing bubbles from soap. Removing the biped, is a much larger collection of data as it calls on animation, collision, and model geometry.

What you should do is first make sure any collision models you have, are not made with the high poly render geometry model. Then also look if any uneeded animations are in the map. Following that, look for any models that are not being used but included in the map.

Sounds, Bitmaps are not included in the tagspace shenanigans, as they can be loaded in on a case by case basis

look into the tag and see if there are any red lines