I have a long-standing issue with Toucan. It affects the latest version, but was also present in at least the two previous versions.
I run differential backups of my PortableApps installation from my USB key to a hard drive on my (Windows 7 64-bit) PC. So every week or so I change the destination folder to force a full backup and each day thereafter a differential to the same folder.
The full backup always completes without issue. The differential backup, however, frequently fails part-way through with a "Toucan has stopped working" message. When I look at the zip file from that backup, sometimes it contains some of the files that should have been backed up, at other times it's of zero length.
The failures always seem to occur during the backing up of cached browser data. It doesn't seem to be specific to any particular browser, though. At various times I've had Google Chrome, Iron and Seamonkey installed on the USB drive and the failures have occurred in backing up files from each of those at one time or another.
As far as I can recall, though, there has never been a failure backing up files from other programmes (including Thunderbird, Filezilla, Pidgin, PopMan and Toucan itself).
Let me know if there's any debug I can run to help to diagnose this.
Regards
Nick