Hi, thanks for your bug report. I have some idea of what the problem may be with the crash. It must be caused by saving settings before having an existing save file. That aspect of it will be fixed in 1.0.6. Until then, however, it's possible to avoid this issue.
I don't know what could be causing the screen to start off so small. If you go into 'your user name'\AppData\Local\Formula_XD\FXDcustomise.ini and set the window width and height to something larger (1920x1200 is as large as it supports) and fullscreen to "1" - then launch the game - well, see if that solves it.
I have just had another urgent bug report recently so if you give it about half an hour, 1.0.5 will be available.
Sorry for the annoyance.