I think I may have found this. One of the quest files in erudnint had a call to plugin::return_items in the mainline code, not inside any SUB.
This was a core quest from peqdb. erudnint/Toresian_Fhabel.pl
I'll post over there and see what they think. Removing that line resulted in the bootup crash going away. I still can't isolate why it only happens some of the time the zone was booted, but it seems completely gone now.
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