I'm still around, although not that often anymore. There are 2 things you can try with Aoc.exe enabled.
1) Go to your ./data/gui/aoc folder and delete Aoc.log, if it exist. Then try and start the game.
2) If first thing didn't work, hold down SHIFT+F8 when you launch the game, to invoke the patcher. It should fix any UI inconsistencies.
The latest version of Aoc.exe generate a log file in your main Age of Conan folder named Aoc.txt. Start Age of Conan with Aoc.exe enabled, as far as you can get, before the error message, then close the game again (if it ever got to launch) and copy the content of Aoc.txt and sent it to me in a PM here, then we'll try and figure it out.
Cheers!