Someone else can give you the technical details better than I but malloc usually refers to a memory allocation error.
I would guess that there is something borked with your pilot model as that is what most often causes the editor to point all 4 feet in the air.
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I think it has something to do with geometryScale. When I changed it to 1.0, the model loaded perfectly but was bloody huge. A pilot the size of a skyscraper.
The geometryScale was formerly 0.0095.
I have another pilot with a geometryScale of 0.0095 which functions perfectly.
It's strange. Maybe geometryScale doesn't like some models.
"You think that you can wipe out an entire civilisation without consequences?" - Rachel
Well its the editor not the game as such, it always has been fairly fussy about new models and really is only expected to deal with correctly formatted xsi files exported from Softimage software of a certain age...Model makers need to conform to its expectations, rather than the other way round.
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BBB-
Submit the broken assets (odf, xsi, do not need textures) on bugzilla and it can be fixed in the future. If you just say "I fixed it" and sweep it under the rug, it's very likely to be a lower priority bug that gets less attention.
Hmm, I imagine the xsi-msh format being fairly strict about its values to 6 decimal places might cause problems when scaling down things by 100 times some data's going to drop to values it does not really want to deal with. Getting model scaled right at geometry scale 1 is definitely what you want to aim for, especially with items like pilots that have other models attached to them, it makes getting things to look right much easier.
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My guess is that the XSI handler has issues with such large (or small) numbers. Its probably losing precision. The MSH code is messy as hell so, crashes abound.
With a repo, I am sure GSH can patch something, even if it is just a graceful error instead of a hard crash.