I can only repeat myself: Please create an FS bug report and attach the BDF which makes convbdf to crash or to produce the indicated error message (which is not a crash BTW). Then there is a good chance that the error will be fixed quickly.
Post Merge: December 13, 2010, 05:34:28 AM
Huh, that must be a huge font! The glyph is 217 pixels wide and 107 pixels high. How did you create it? Are you sure that's your intended size?
And indeed: in convbdf, there is a buffer of fixed size (2048) that is used for internal processing. This buffer is too small to process such a huge glyph.