By the way, how many toolbars did you have roughly?
The information that I found says that there could be another url length limit around 500 (officially urls in IE can be 2083 characters long). This should not anymore an issue in ToolbarEditor 1.0.4.
With this test in the Ruby Console we could confirm whether this caused the error:
count=0;w=UI;;WebDialog.new;w.set_html("<html></html>");w.add_action_callback("a"){|d,p| count=p.length if p.length>count};w.show{ w.execute_script("var s='';for(var i=0;i<3000;i++){ s+='b';window.location.href='skp;a@'+s;}") }
It then envokes an Internet Explorer error (I get "Could not complete the operation due to error 800700a").
When I then enter " count" into the Ruby console, I get 2077.
Do you get the same error that you got previously ("The data area passed to a system call is too small")?