It's not telling me much....and what it is telling me is contradictory: HD can access your hard drive, since it _is_ remembering _some_ of its state from the last session. But it's not remembering all of it (only one character is re-opening). There is NOTHING in the code that could do that.
The same goes for the export bit.
This seriously sounds like your system is horked in a major way. Are you experiencing issues with any other applications?
Either way, the only thing I can think of is for you to post a series of exact steps that you're taking so that I can try to replicate them on my end. I mean everything. Uninstall HD, delete the install directory, and re-install it to start from a "blank slate" and then post the steps. Like the following:
1. I double click the icon on my desktop and launch HD
2. HD opens and I select File -> Open Character and select the file C:\Documents and Settings\Dan Simon\Desktop\someCharacter.hdc
3. someCharacter.hdc opens and I select File -> Open Character and select the file C:\Documents and Settings\Dans Simon\Desktop\someOtherCharacter.hdc
4. someOtherCharacter.hdc opens and I select File -> Preview Character.
5. The Export Template selection dialog comes up and I select....
And so on.
Be precise.
And then post (or email me) the trace.log file once you close the session.
White Hats are for CISSPs
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