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73416ba
(Get the code!)
The only difference between the two tests asked for in comment 61 is whether or not inkex.localize() is run before the second Inkscape instance is spawned via Popen().
inkex.localize() modifies the environment on Windows (sets/changes $LANG), which seems to affect the spawned second Inkscape (trunk) instance. You could test (re-read and write to file) the value of os.environ['LANG'] at the end of localize(), or right before calling Popen(), maybe that gives another clue as to what happens.
I'm running out of ideas what else to test, sorry, and due to the lack of current devel snapshot builds for Windows I can't reproduce the crash locally either ...