Hi Tom
I think that I see the problem.
You are combining uTasker_boot.bin with uTaskerV1-4.elf.bin as first step.
The problem is that these are not raw binary file but are MOTOROLA binary files. The result is uTaskerHVC_APP.bin, which is a mixture of two MOTORLA binary files with a block 0xff joing them.
Everything goes fine in the uTaskerConvert step until this area of 0xff is hit and then the attempt to interpret it causes wild results and a crash.
Initially I wondered whether it was a tactic in the MOTOROLA binary format that could insert 0xff so I attempted to just copy all 0xff until a non-0xff was encountered and then start with the header interpretation again. Although this is possible there is risk involved in case the number of 0xff between the areas were to be small and not guarantee detection of it.
Therefore I suggest using uTaskerConvert first on the two input files before then combining them. The the final conversion step will be working directly with a binary input and so not have this difficulty. The utility was adapted due to the CW behavior as seen from the release notes to V1.6:
Version V1.6 14-05-2011
===================
Added capability to convert Motorola binary to raw binary output. This is useful for CodeWarrior binary output
which can otherwise not be used directly as a code image - after the conversion the content is in raw binary format
and so suitable for general binary program use.
User "uTaskerConvert uTasker_BM.bin raw.bin -b"
Regards
Mark