[8FS_Bulau]

put the F-84 folder into the enabled Mods folder
put the air ini line into the MODS /STD/COM/maddox/il-2/objects/air ini
put the buttons file v 4.2 into MODS/STD/GUI/game/

These are the things that could be responsible for a 60% CTD, and everything you've described is correct, so I can't say what has gone wrong. I've suggested everything I can think of. All I can suggest is double-check every step. If you comment out the F84F line in the air.ini, does that fix the 60% CTD?

[CPS.fraggmann]

Yup..I added "//" the the front of the F-84 line in the air ini and still crashes.
I also tried to install the Cougar and still crashes. I got a fresh copy of the buttons
file and tried that as well and crashed at 60%

[8FS_Bulau]

OK, then it's not the F84F per se, but something else. And you have not added anything else to air.ini, right?
And this is UP 2.0, right? What about the Bugfix patch...did you install that? Because that changes some things, but you need to update things in the MODS folder by copying them from the Files folder after installing the patch, as described here:

http://ultrapack.il2war.com/index.php/topic,1536.0.html

[CPS.fraggmann]

I got it!! Half way.. Im not sure what the problem was exactly but the issue resolved itself it seems after I installed the new 2.0m patch. All works good now when I use UP2.0..HSFX still crashes at 60%.
Hey Bluau really..thank-you for all your efforts... and to the others that tried to assist as well...thanks to you all
George Lieblein........CPS_fraggmann