Mark,

I got your file and was able to export without a problem. I tried 128x128 and 4096x4096 BMP and TIF. Here's the steps I used in case I've missed something, Open Carrara, open sphere.car, select the vertex object, switch to modeling room, switch to UV Mapping tab, click UV editor, switch to display tab, hit export.

I can't see how Grows would have anything to do with that, but I have seen stranger things. Double check to make sure that you don't have two copies of Anything Grows in the extensions folder. I've see weird stuff happen when there are two copies of the same plug-in. Also try reseting your preferences using File|Reset Preferences. I've seen a lot of really bizarre behavior come out of a corrupt preference file, but usually only on the Mac. You also mentioned getting other IO errors and file problems, have you done a check disk lately? It's been a long time since I've used 98, but it's probably available by right clicking on your drive in explorer and selecting properties.

Regards,
Eric Winemiller
Digital Carvers Guild
3D plug-ins for Carrara
http://digitalcarversguild.com

Eric Winemiller
Digital Carvers Guild
Carrara and LightWave plug-ins