I managed to find part of the problem. It seems that if the config is reset there is no default WDTVEXT variable and the box boots with WDTVEXT=ON if it can't find the variable. I'm working on a patch to fix this. However, this only solves part of the problem. It means that you can boot and use the box without issues as long as you don't enable WDTVEXT. If I enabled WDTVEXT with the default config I got the same crash.
I left the unit to do some stress testing last night, but alas, it seems to have crashed worse because I can't access it over serial (I need to physically reboot it), so I will test it later. I'll do more tests with my complete config and then try to remove items (I have about 400 config items) and do repeted tests to see if there is one config item that causes this commotion... It will take a while. In the meantime I'll work on adding the extra features we've discussed...
Sorry to hear about your viral state, kroetkroet. Hope you get well soon...