Good news for me is that I have 2 out of 3 running Castaway correctly ... but that third one ..
I presently own 5 computers which have AC running on them. I have been playing AC since June 2000 and have used Decal utilities for 8 years. And I have been using Castaway since 2002 I believe (cant remember when I started

).

Three of the clients have Castaway installed. Two are fresh installs today. One of those never had Castaway on it before (XP Pro SP3 client was reimaged 6 months ago) and Castaway works correctly on it. The other is a three year old with XP Media Center SP3, which had a (unsuccessfully used) Castaway 1.7.0.851 installed. I uninstalled the old and installed a freshly downloaded 1.7.0.894. This client resembles this thread.

The base problem seems to be accessing the base and/or toon XML files. The files do exist. I compared them via "Beyond Compare" to the files on the good client (XP Pro above) and found no differences in content and placement.

No base info is populated in any of the fields on any of the Castaway panels IG, when AC/Decal/Castaway is started up. Manually filling in the options and fields are not saved when exiting the AC client session.

Per the thread, "MSXML 4.0 SP2 Parser and SDK" was (re)installed and the same results happen.

Note : Again, this is based on a Castaway 1.7.0.894 installation. There was a previous Castaway 1.7.0.581 installed on this client that was uninstalled before installing this version on this client.
The following debug was captured during the use of the "Reload XML" option on the Main tab on Castaway.
_________________________________________________________
Castaway_Debug.xml
<debug>
<log>
<date>03-14-2009 11:38:30 am</date>
<message>Settings.bas : SaveSettingsXMLString(chkLogDebug, True) Error: 91, Object variable or With block variable not set, Location Open BotSettings.xml - chkLogDebug</message>
</log>
<log>
<date>03-14-2009 11:38:32 am</date>
<message>: ReloadXMLFiles() Error: 91, Object variable or With block variable not set, Loc: Re-Loading C:\Documents and Settings\me\My Documents\Castaway\Settings\Solclaim\MyBuffBot\BotSettings.xml</message>
</log>
<log>
<date>03-14-2009 11:38:36 am</date>
<message>Settings.bas : SaveSettingsXMLString(chkDebug, False) Error: 91, Object variable or With block variable not set, Location Open BotSettings.xml - chkDebug</message>
</log>
</debug>
_________________________________________________________
Castaway_Error.xml
<errors>
<error>
<date>03-14-2009 11:37:01 am</date>
<message>: ReloadXMLFiles() Error: 91, Object variable or With block variable not set, Loc: Re-Loading C:\Documents and Settings\me\My Documents\Castaway\Settings\Solclaim\MyBuffBot\BotSettings.xml</message>
</error>
<error>
<date>03-14-2009 11:37:01 am</date>
<message>Settings.bas : LoadSettingsXMLString(bNewbie, True) Error: 91, Object variable or With block variable not set, Location: Open BotSettings.xml - bNewbie - Default: True</message>
</error>
<error>
<date>03-14-2009 11:37:01 am</date>
<message>Settings.bas : SaveSettingsXMLString(bNewbie, False) Error: 91, Object variable or With block variable not set, Location Open BotSettings.xml - bNewbie</message>
</error>
<error>
<date>03-14-2009 11:37:01 am</date>
<message>Settings.bas : LoadSettingsXMLString(SelfBuffs, buffbot) Error: 91, Object variable or With block variable not set, Location: Open BotSettings.xml - SelfBuffs - Default: buffbot</message>
</error>
<error>
<date>03-14-2009 11:37:02 am</date>
<message>Spells.bas : LoadSelfBuffs() Error: 91, Object variable or With block variable not set, Location: Open hub.SpellsXML</message>
</error>
<error>
<date>03-14-2009 11:37:02 am</date>
<message>Settings.bas : LoadSettingsXMLString(SelfBanes, allbane) Error: 91, Object variable or With block variable not set, Location: Open BotSettings.xml - SelfBanes - Default: allbane</message>
</error>
<error>
<date>03-14-2009 11:37:02 am</date>
<message>Spells.bas : LoadBanes() Error: 91, Object variable or With block variable not set, Location: Open BotSpells.xml</message>
</error>
<error>
<date>03-14-2009 11:37:02 am</date>
<message>Spells.bas : getSelfBuffArray( ) Error: 91, Object variable or With block variable not set, Location: Open BotSpells.xml</message>
</error>
<error>
<date>03-14-2009 11:37:02 am</date>
<message>Settings.bas : LoadSettingsXMLString(iPlayerWand, 0) Error: 91, Object variable or With block variable not set, Location: Open BotSettings.xml - iPlayerWand - Default: 0</message>
</error>
<error>
<date>03-14-2009 11:37:02 am</date>
<message>clsWorld : GetWieldedID() Error: 91, Object variable or With block variable not set. Line# 50</message>
</error>
<error>
<date>03-14-2009 11:37:02 am</date>
<message>Settings.bas : LoadSettingsXMLString(OutOfRangeDistance, 0.1) Error: 91, Object variable or With block variable not set, Location: Open BotSettings.xml - OutOfRangeDistance - Default: 0.1</message>
</error>
<error>
<date>03-14-2009 11:37:02 am</date>
<message>clsWorld : IDPlayers() Error: 91, Object variable or With block variable not set. Line# 30</message>
</error>
<error>
<date>03-14-2009 11:37:14 am</date>
<message>clsWorld : GetWieldedID() Error: 91, Object variable or With block variable not set. Line# 50</message>
</error>
<error>
<date>03-14-2009 11:37:14 am</date>
<message>Settings.bas : SaveSettingsXMLString(iPlayerWand, 0) Error: 91, Object variable or With block variable not set, Location Open BotSettings.xml - iPlayerWand</message>
</error>
<error>
<date>03-14-2009 11:37:36 am</date>
<message>: ReloadXMLFiles() Error: 91, Object variable or With block variable not set, Loc: Re-Loading C:\Documents and Settings\me\My Documents\Castaway\Settings\Solclaim\MyBuffBot\BotSettings.xml</message>
</error>
<error>
<date>03-14-2009 11:38:29 am</date>
<message>Settings.bas : SaveSettingsXMLString(chkDebug, True) Error: 91, Object variable or With block variable not set, Location Open BotSettings.xml - chkDebug</message>
</error>
<error>
<date>03-14-2009 11:38:30 am</date>
<message>Settings.bas : SaveSettingsXMLString(chkLogDebug, True) Error: 91, Object variable or With block variable not set, Location Open BotSettings.xml - chkLogDebug</message>
</error>
<error>
<date>03-14-2009 11:38:32 am</date>
<message>: ReloadXMLFiles() Error: 91, Object variable or With block variable not set, Loc: Re-Loading C:\Documents and Settings\me\My Documents\Castaway\Settings\Solclaim\MyBuffBot\BotSettings.xml</message>
</error>
<error>
<date>03-14-2009 11:38:36 am</date>
<message>Settings.bas : SaveSettingsXMLString(chkDebug, False) Error: 91, Object variable or With block variable not set, Location Open BotSettings.xml - chkDebug</message>
</error>
<error>
<date>03-14-2009 11:38:36 am</date>
<message>Settings.bas : SaveSettingsXMLString(chkLogDebug, False) Error: 91, Object variable or With block variable not set, Location Open BotSettings.xml - chkLogDebug</message>
</error>
</errors>
_________________________________________________________
Decal Export
Decal (DenAgent.exe) version: 2.9.6.0
type, enabled, name, version, clsid
Plugins, 0, VMT.dll, 0.2.0.1, {CFA4F35C-4597-44BB-8382-E62D434923D7}
Plugins, 1, Decal Hotkey System, 2.9.6.0, {6B6B9FA8-37DE-4FA3-8C60-52BD6A2F9855}
Plugins, 0, GoArrow, 1.2.0.1, {46BBF551-8578-4A59-B2FB-B5D9F4C719FA}
Plugins, 0, Alinco Buffs, 1.5.1.0, {58A8364F-99D7-4FE5-BAE9-D0CBF0329055}
Plugins, 0, MiniMap, 1.1.0.104, {92C09018-E815-4C22-987B-8E553154146E}
Plugins, 0, Virindi Tank, 0.3.0.23, {642F1F48-16BE-48BF-B1D4-286652C4533E}
Plugins, 0, ScrollReader3, 1.1.1.0, {1D9551D0-E3EF-4D2F-9953-6469550497DC}
Plugins, 0, Mob Tracker, 1.4.0.0, {0C212D60-8708-4043-A09B-E6C0387A0A8D}
Plugins, 0, Tworocks Shortcuts.dll, 1.1.0.3, {70172151-A3CD-46ED-A9FE-17B036BF2C5A}
Plugins, 0, Cast It! 1.00, 1.0.2.0, {DECA1000-10C8-423C-B851-5CDBCDCA58DF}
Plugins, 0, Alinco, 1.4.9.7, {4338186E-7AE8-4B9E-985D-98D692036EA8}
Plugins, 0, SkunkVision, 1.0.0.7, {B8B64AFD-3D96-490D-A70B-CE962227148A}
Plugins, 0, Tings, 1.0.0.42, {864F2945-A564-4C8D-A36F-0CAF267F7612}
Plugins, 0, HWAC_Stats.dll, 1.4.0.4, {1D17D4A2-D62C-46B5-881E-A06EEF47D7DF}
Plugins, 0, AKA, 1.0.1.1, {5447EB5A-A6BC-469A-BC4B-CEF1768B0C7C}
Plugins, 0, Quest Timer, 2.4.0.2, {BB51962C-2EEE-4E67-A032-EEC1F11E66C8}
Plugins, 0, Radar Add-on, 1.2.0.49, {CA23F8D7-7E71-423A-A928-BC5CDD8FBD96}
Plugins, 0, Spellbar Saver, 2.2.0.1, {C9D83ECD-28C6-4D9D-B994-984DB26B5C2E}
Plugins, 0, Mule Trade It!, 0.0.0.368, {9D762D6E-6444-485A-B242-C50386013763}
Plugins, 0, Imp Inventory, 1.0.0.4, {006D1FA0-DDB5-42BC-9DAA-6D1DC696712E}
Plugins, 1, CastAway, 1.7.0.894, {4EB455CB-A2DA-44B6-90F2-09517A4B1476}
Plugins, 0, LifeTank X, 11.9.0.9, {910C0F8E-827A-4E35-A980-50D57D0B1296}
Plugins, 0, AC+, 1.1.0.1164, {5ACB7319-8E15-4A4A-A24D-59180DA1DF49}
Plugins, 0, Call It! Vsn 1.0, 1.0.0.0, {DECA1000-4354-4329-B003-9592F948C1A3}
Network Filters, 1, Echo Filter 2, 2.9.6.0, {34239EAD-6317-4C40-A405-193BA5232DD8}
Network Filters, 1, Alinco Filter, 1.4.2.0, {375A7C84-B4FD-49BB-B63D-15CCC004E979}
Network Filters, 1, Character Stats Filter, 2.9.6.0, {4540C969-08D1-46BF-97AD-6B19D3C10BEE}
Network Filters, 1, World Object Filter, 2.9.6.0, {53092D1B-F0B0-46FF-BF11-8F031EC9B137}
Network Filters, 1, Decal FileService, 2.9.6.0, {5E9B2FC3-C251-4589-8CE3-2BCA542B98B6}
Network Filters, 1, Identify Queue Filter, 2.9.6.0, {B0C05A9A-273D-4BC4-B7BA-E27CF94C8EF4}
Network Filters, 1, Population Filter, 0.0.2.5, {39EACE9F-1BF2-4E4F-BFBC-2FD9EB76A47B}
Network Filters, 1, Darkside Filter, 11.9.0.9, {F93FD48F-BA68-4BF5-A7B3-7908D1634331}
Services, 1, Decal .NET Lifetime Service, 2.9.6.0, {71A69713-6593-47EC-0001-0000000DECA1}
Services, 1, Decal Dat Service, 2.9.6.0, {37B083F0-276E-43AD-8D26-3F7449B519DC}
Services, 1, Decal Render Service, 2.9.6.0, {FB3C8286-88ED-4B4D-B413-94B40F346239}
Services, 1, Decal Inject Gateway Service, 2.9.6.0, {FEFE5CAB-10E4-404F-AD4D-184BCB506099}
Services, 1, Decal Input Service, 2.9.6.0, {B33307BA-706D-474A-80B9-70BB8D13EF3E}
Services, 1, Decal Networking Service, 2.9.6.0, {C8C406F8-BA2E-4964-8B04-FF38394A8E0E}
Services, 1, Decal D3DService, 2.9.6.0, {F0CC07A0-2C89-4FA4-9356-714665BC2F8B}
Surrogates, 1, Decal.Adapter Surrogate, 2.9.6.0, {71A69713-6593-47EC-0002-0000000DECA1}
Surrogates, 1, Prefilter Network Filter Surrogate, 2.9.6.0, {443D4A68-5422-4E0C-9460-973F8FBDB190}
Surrogates, 1, ActiveX Plugin Surrogate, 2.9.6.0, {7559F22F-C56F-4621-AE08-9C354D799D4B}
Surrogates, -1, Version 1 Plugin Surrogate, 2.9.6.0, {3D837F6E-B5CA-4604-885F-7AB45FCFA62A}
Input Actions, 1, Delay Input Action, 2.9.6.0, {324D76B8-D8C7-4A81-B867-E4E1F874E488}
Input Actions, 1, Mouse Move Input Action, 2.9.6.0, {57D18578-0BF0-4DE5-A0A9-E7CB531C0429}
Input Actions, 1, Restore Input Action, 2.9.6.0, {6EE2F682-7129-44BE-84B9-787BAE35EC1C}
Input Actions, 1, Polled Delay Input Action, 2.9.6.0, {762335B2-2274-4BB4-8B1F-F7286C949FF7}
Input Actions, 1, Typing Input Action, 2.9.6.0, {9CDCEEDC-F8AC-42D5-9A05-52B9346D00A4}
Input Actions, 1, Event Input Action, 2.9.6.0, {D6E4BD19-4900-4515-BCE2-A9EA4AAE2699}
Operating System:
Microsoft Windows XP Professional Service Pack 3 (Build 2600)
[Protected Storage Service] : Automatic
Decal Settings
[Injection Method] : Timer (Default)
[Portal Path] : C:\Program Files\Turbine\Asheron's Call - Throne of Destiny\
[Launcher App] : acclient.exe
[Update URL] :
http://update.decaldev.com
[memlocs.xml] : 24536 bytes, Version 0.0.11.2178
[messages.xml] : 54173 bytes, Version 2008.04.15.1
[Video Memory] : 660570048
D3DX Libraries (Only d3dx9_30 is required)
[d3dx9_24.dll] : Installed (9.5.132.0)
[d3dx9_25.dll] : Installed (9.6.168.0)
[d3dx9_26.dll] : Installed (9.7.239.0)
[d3dx9_27.dll] : Installed (9.8.299.0)
[d3dx9_28.dll] : Installed (9.10.455.0)
[d3dx9_29.dll] : Installed (9.11.519.0)
[d3dx9_30.dll] : Installed (9.12.589.0)
---Support Libraries ---
Note: The following libraries are not necessary for Decal to function and are only provided to be of use to plugin developers.
.NET Frameworks
[v1.0.3705] (1.0 Final) : Installed
[v1.1.4322] (1.1 Final) : Installed (Service Pack 1)
[v2.0.50215] (2.0 Beta 2) : Not Installed
[v2.0.50727] (2.0 Final) : Installed (Service Pack 1)
C++ Libraries
[msvbvm60.dll] : Installed (6.0.98.2)
[atl70.dll] : Not Installed
[mfc70.dll] : Not Installed
[msvcr70.dll] : Installed (7.0.9466.0)
[msvcp70.dll] : Not Installed
[atl71.dll] : Installed (7.10.3077.0)
[mfc71.dll] : Installed (7.10.3077.0)
[msvcr71.dll] : Installed (7.10.3052.4)
[msvcp71.dll] : Installed (7.10.3077.0)
Microsoft XML Libraries
[msxml3.dll] : Installed (8.100.1048.0)
[msxml4.dll] : Installed (4.20.9870.0)
---Video Device Information---
[Device] : ATI RADEON XPRESS 200M Series
[Device Name] : \\.\DISPLAY1
[KeyDeviceID] : Enum\PCI\VEN_1002&DEV_5A62&SUBSYS_FF311179&REV_00
[KeyDeviceKey] : \Registry\Machine\System\CurrentControlSet\Control\Video\{3BD54931-20B0-449D-9FED-D481CF8E8BBC}\0000
[Manufacturer] : ATI Technologies Inc.
[ChipType] : ATI RADEON XPRESS 200M Series (0x5A62)
[DACType] : Internal DAC(400MHz)
[Revision] :
[MemoryLocalised] : 256.0 MB
[MemoryEnglish] : 256.0 MB
[DisplayLocalised] : 1280 x 1024 (32 bit) (60Hz)
[DisplayEnglish] : 1280 x 1024 (32 bit) (60Hz)
[DisplayWidth] : 1280
[DisplayHeight] : 1024
[DisplayBpp] : 32
[RefreshRate] : 60
[MonitorName] : Plug and Play Monitor
[MonitorMaxRes] : 1600,1200
[DriverName] : ati2dvag.dll
[DriverVersion] : 6.14.0010.6587
[DriverAttributes] : Final Retail
[DriverLangEnglish] : English
[DriverLangLocal] : English
[DriverDateEng] : 12/12/2005 00:41:04
[DriverDateLocal] : 12/12/2005 00:41:04
[DriverSize] : 252928
[MiniVdd] : ati2mtag.sys
[MiniVddDateEng] : 12/12/2005 00:40:44
[MiniVddDateLocal] : 12/12/2005 00:40:44
[MiniVddSize] : 1414656
[Vdd] : n/a
[RenderWindow] : Yes
[Beta] : No
[Debug] : No
[Signed] : No
[SignValid] : No
[Identifier] : {D7B71EE2-1922-11CF-726B-3BDFA1C2CB35}
[DDIVer] : 9
[DDIVerEng] : 9 (or higher)
[DDIVerLocal] : 9 (or higher)
[iAdapter] : 0
[VendorID] : 0x1002
[DeviceID] : 0x5A62
[SubSystemID] : 0xFF311179
[RevisionID] : 0x0000
[WHQL Level] : 0
[NoHardware] : 0
[DDAccelEnabled] : Yes
[3DAccelExists] : Yes
[3DAccelEnabled] : Yes
[AGP Enabled] : Yes
[AGPExists] : Yes
[AGPExistsValid] : Yes