Do you upload those facegen images (updated images, ect) with the HTML reports file? If not then it can't be related to facegen. If yes then make sure you try to run the reports
without adding updated images (change the commish portal HTML creation settings). It sounds like you tried that but make sure about that. There are some screen's in the game where you can turn images off but that input is completed ignored by the game and images are generated anyway
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Regarding the initial player page that crashed the game and the 2nd player page that crashed the game (after you deleted the first player) :
- "the player was recently on a team, then cut during the playoffs" <---- Is that what happened to the 2nd player as well? I seem to recall some old game issue with releasing players during the play offs...
- Is there anything else the two players might have in common? Were they both released, were they both on the same team, etc.?