I think i've solved it.
Our problem in the the way load2 outputs and we are missing original img/lod parser.
After the tests, the attract screen is the first place we get actual gfx on screen.. i figured it might be this last night as i couldn't sleep.
I took the trog source, it has IMGTBL.ASM already built in it.
I used load2 to generate it again from trog.lod. What could go wrong. Well, a lot apparently.
Quick screenshot, left is load2, right is original included with trog src.
However, i think we only need the GLO output from load2, both IMGTBL.ASM and BGNDTBL.ASM are included in the BACKUP folder..
On the left side is the one we are currently using built by load2/newload exe. On the right side the original IMGTBL.ASM from SmashTV backup folder.
You can see the problem where it puts part of the data in a second .WORD and the location .LONG does not match.
So the build we have going now reads from wrong gfx locations and crashes in Mame, and shows random corruptness on real H/W.
Might be some misalignment with gfx even in the files from backup, i don't know. Also they need hex fixings >xxxx to 0xxxxH and bla bla.
If we fix this and build, we still have an issue where we are missing COBRA.TBL, FLATFACE, GALAGAS etc tables...
But at least title screen should look better/work? Maybe the game will crash once those sprites go on screen.
If i had the time, i would be building it right now, but soon our daughter will wake from her nap so nope. sry.
Looking forward to some new screenshots from you hopefully!
I'll be back later tonight!
P.S. i found the source for load2 if you want to fix this or build a new one from scratch. Check PM.