I don't know if this is of any use to you or not, but my build of r163 crashed reliably on startup when loading zpack.pk3.  I played plenty of other WADs and they were OK.  
Unfortunately (kind of), I assumed that r164 would also have the problem so I upgraded to it intending to make a debug build and then make a bug report, however the crash doesn't seem to happen with r164 (release or debug).  I have no easy way to go back to an earlier build.
However, just in case the crash was related to the startup bug that I reported before, I thought you might want to see if it happens for you too if you still have a test version of r163 kicking around.
[edit]For what it's worth, it happens with Nash's build of r161.  Here's a crash report from that build.[/edit]
			
			
									
						
										
						r163 crashes on startup when loading zpack.pk3
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				Enjay
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