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Does it segfault right on start up or is it somewhere later? Can you reproduce it back, by restoring the old .conf file again and taking a stack-trace dump for the record? Remember to do that with a debug build (./configure --enable-debug).

A diff -u against the old and newer .conf files would be also interesting. Even more interesting after you replicate all your older options into the newer as much as possible, please.

Cheers