Hmmm...make sure you're setting a large stacksize for your AOLserver threads. I've run out of stack space running OACS 4 with a hacked-up 3.2.5 nsd.tcl init file which didn't have a large stacksize defined. That caused stacktraces not crashes (i.e. AOLserver didn't die it just
killed my thread) but it's worth your time to check nsd.tcl...
Other than that I don't have any brilliant ideas. After all, our app code shouldn't be able to crash AOLserver. Which version are you using?