As I said over on Sega-16, my wife and I just played through the whole game on real hardware (EverDrive-MD on a Genesis Model 2) and using the latest patch. You all did a wonderful job with it. Here are the issues I found:
Crashes and Graphical Issues
The only crash I saw was in the battle vs. Arthur in the room with the proton gun. When I threw the uppermost "Part" at him first, the game immediately crashed, and he only got out the letter "A" (instead of saying "Aargh" or whatever). I had to power-cycle the console to resume play, but when I did, I threw a different item at him first, threw the top "Part" item at him last, and had no problems. (However I reset again when I realized that I probably didn't need to throw anything at him.)
The game itself was free of graphical issues, but the ending credits had some problems. Almost all of the job titles, and many of the people's names, had their last couple letters corrupted. Also, the very last screen had a white-dot pattern overlaying most of the screen, but not the portion to the left of the final character portrait. This looked to me like tile corruption.
Spelling/Grammar Errors and Typos
Here's what I found, with errors on the left and corrected version on the right. Sorry I can't specify exactly where all of it was:
adjustement > adjustment
embarassing > embarrassing
other various > should be "various other"
unusuable > unusable
syncronize > synchronize
morse code > Morse code
vaccuum > vacuum
the each particle > I think it should just be "each particle", IIRC
Acccording > According
purprose > purpose
dissassemble > disassemble (not sure whether I actually saw this one, it went by too quickly to be sure)
principle mission > principal mission (grammatical error)
Articificial > Artificial
Hybernation > Hibernation
as good as dead.I > as good as dead. I (space is missing)
There were also two other bits of weirdness:
"Material Room" vs. "Materials Room" -- it showed up with both names, but should probably be standardized.
Finally, at one point Keith said "...Mark is..." for no apparent reason, and it didn't really make sense. Is that in the original?
BTW the character names at the beginning (overlaid in white atop the graphics) are very difficult to read, at least using composite video on a CRT. But it's not a big deal.
Huuuuuge thanks for all your work on this!