I have also been having this problem with the use of the mods included in MCpatcher as well as TMI. When trying to start Minecraft with the pack pre-selected It crashed wit this Error report after before reaching the main menu.
Show ---- Minecraft Crash Report ----
// I'm sorry, Dave.
Time: 8/11/13 8:09 PM
Description: Registering texture
big: Unable to fit: minecraft:mcpatcher/ctm/clay/700.png - size: 128x128 - Maybe try a lowerresolution texturepack?
at bid.c(SourceFile:63)
at bih.b(SourceFile:87)
at bih.a(SourceFile:54)
at bij.a(SourceFile:69)
at bij.a(SourceFile:58)
at bij.a(SourceFile:49)
at ats.O(SourceFile:378)
at ats.d(SourceFile:599)
at net.minecraft.client.main.Main.main(SourceFile:101)
A detailed walkthrough of the error, its code path and all known details is as follows:
---------------------------------------------------------------------------------------
-- Head --
Stacktrace:
at bid.c(SourceFile:63)
at bih.b(SourceFile:87)
at bih.a(SourceFile:54)
-- Resource location being registered --
Details:
Resource location: minecraft:textures/atlas/blocks.png
Texture object class: bih
Stacktrace:
at bij.a(SourceFile:69)
at bij.a(SourceFile:58)
at bij.a(SourceFile:49)
at ats.O(SourceFile:378)
-- Initialization --
Details:
Stacktrace:
at ats.d(SourceFile:599)
at net.minecraft.client.main.Main.main(SourceFile:101)
-- System Details --
Details:
Minecraft Version: 1.6.2
Operating System: Windows 7 (amd64) version 6.1
Java Version: 1.6.0_24, Sun Microsystems Inc.
Java VM Version: Java HotSpot(TM) 64-Bit Server VM (mixed mode), Sun Microsystems Inc.
Memory: 246369968 bytes (234 MB) / 515702784 bytes (491 MB) up to 954466304 bytes (910 MB)
JVM Flags: 2 total; -XX:HeapDumpPath=MojangTricksIntelDriversForPerformance_javaw.exe_minecraft.exe.heapdump -Xmx1G
AABB Pool Size: 0 (0 bytes; 0 MB) allocated, 0 (0 bytes; 0 MB) used
Suspicious classes: [com.prupe.mcpatcher.MCPatcherUtils, Config, MCLogger, ...], [com.prupe.mcpatcher.cc.ColorizeItem, Colorizer, ColorMap, ...], [com.prupe.mcpatcher.cit.CITUtils, OverrideBase, ItemOverride, ...], [com.prupe.mcpatcher.ctm.CTMUtils, TileOverrideIterator, ITileOverride, ...], [com.prupe.mcpatcher.hd.AAHelper, FontUtils, MipmapHelper, ...], [com.prupe.mcpatcher.mob.MobRandomizer]
IntCache: cache: 0, tcache: 0, allocated: 0, tallocated: 0
Launched Version: 1.6.2-mcpatcher
LWJGL: 2.9.0
OpenGL: Intel(R) HD Graphics Family GL version 3.1.0 - Build 8.15.10.2372, Intel
Is Modded: Very likely; Jar signature invalidated
Type: Client (map_client.txt)
Resource Pack: Sphax PureBDcraft 128x MC16.zip
Current Language: English (US)
Profiler Position: N/A (disabled)
Vec3 Pool Size: ~~ERROR~~ NullPointerException: null
When switching to the pack from within a session, many common textures are replaced with pulsing orange with the rest remaining default.
I hope this helps. None of these problems were experienced with a vanilla client or before the 1.6.2 pack update. Worked fine with the 1.6 pack
P.S. The x64 pack still works.