Got it to crash straight away with this layout :
2010/10/17 10:09:10.93 Info: SetLayout: Layout Name= N64 (Project64 1.6)
2010/10/17 10:09:10.95 Info: Loading layout: C:\Executable\N64 (Project64 1.6).mll
2010/10/17 10:09:11.17 Debug **: GetLayoutPath: all files in MaLa dir in layout sub dirs C:\Emulation\FrontEnds\Mala\MaLa171\layouts\N64 (Project64 1.6)\N64.PNG
2010/10/17 10:09:11.43 Error: Exception Message: Access violation at address 005D9F3C in module 'MaLa.exe'. Read of address 03270000, Object Function: LoadPictureCustom, Exception Class: EAccessViolation, Object Class: TPopupList
2010/10/17 10:09:15.46 Info: Showing taskbar
2010/10/17 10:09:15.48 Debug **: ShowMouse:
2010/10/17 10:09:15.48 Error: AppException: Terminating MaLa
I will investigate.
Later..The error does not seem to be consistent.

It makes me think it is a bug in the Delphi graphics lib's.
Anyway, I changed MaLa so
- It doesn't crash in this scenario
- It has a 2nd attempt loading the graphic...
Please try this and see if you can work out if there is any set pattern. I give up for now.
http://www.malafe.net/files/download/MaLa1720.zip