Tried the new one (POL097-2007-08-23 RC5 Coregina (VS.NET 2003) compiled on Oct 2 2007 11:31:44), still no luck
Yeah, I've recompiled the script. Heading to bed now, 1:30 am here..

Because you are trying to unpack BAD data, simple enough. Unless you can ensure the packed data is correct, do NOT use unpack on it.
I don't have much choice whether to use unpack or not when using AUX :)

Now, you want to prevent against denial of service..... set up IP rules for the ports using ...

Seems it incorrectly handles many "corner cases". Some of them cause thread exceptions which include bad allocations and excessive memory usage peaks. If you have AUX listener enabled, you are open to DOS attacks (btw, why on earth AUX uses packed format, not raw text data?).

packed := "S-1 ...

There are two options:
1 - Use a dictionary data-type (associative array)
2 - Use the [] operator on the struct because insert isnt a method for structs.
According to Racalac's Escript guide, struct is internally a dictionary and dictionary methods work for structs.

var spell := struct;
spell ...

I have a config file which contains object (spell) properties:

Spell 1
{
Name Ultimate Spell Of Mass Destruction
PowerWords Kal Vas Mon Ty Pyt Hon
ManaCost 50
Difficulty 50
CastType Normal
TargetType Mobile
Notoriety Harmful
ResistType Damage
Animation Target
Sound 0x209
CastCycles 4 ...