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Just carrying on a bit with this... a strange thing happened, i tried setting up an extra (5th) AI only flight for this CoralSea map, with the 5th flight starting from a carrier - can you believe, i went into QMB and tried it - with one enemy flight entered into the QMB, i started the mission, and = lo and behold - the 5th enemy flight spawned on the carrier!
I thought i was onto something, but i then tested it with no enemy flights in QMB, and instantly got the Corrupt Data File error....after changing it back to just 4 flights, i still get the error, so testing continues...(slowly 8) )