well, to answer your question in a short way: if you have modded an older version of BAT, adding stuff to ini files, as soon as you copy over a new version of BAT with those additional thingies in the BAT module folders, all hell will break loose and your game will crash, either at 60% (air.ini) or at 70% (ship, objects, stationary.ini)
so if you want to have a current version of BAT - AND - additional stuff, you need to apply all those ini changes for the stuff you want to add to BAT again!!!
a crash at 60% points towards missing entries (or missing classfiles) for aircraft though; it can be of course that your game loaded up to 60%, even finishing loading aircraft and as soon as it tried to initialize other stuff like ships, objects etc where there are classfiles but no ini entries, it crashes (at 70%), the crash happening so fast that you do not even see the 70% load indicator...
so in a nutshell, if you want to add aircraft, ships, objects to BAT , you have to add the respective ini entries....
if you have more specific questions, please open a thread in the tech help section though, this is the release thread and it should not be filled with tech questions and problems that do not come from the installer itself, as this works as advertised....