Hi ?ferret,
Strange problem you've got there with SI crapping out on you after 5 minutes. You got a temperature monitor on your CPU or something that goes apeshit if it's not getting feedback while in SI?
Anyway, for what it's worth, I usually do raw dumps with Icedumps /DUMP command, rather than using /PEDUMP, because I like to have the Raw Offsets and Sizes of the sections in the dumped file match up with those of the Virtual image I just dumped from. Addresses as seen in W32Dasm or SI directly match up with the offsets in a hex editor, and it's easy to find the IAT and other sections. Not such a big deal if you know a /PEDUMP will produce a working exe, but if the Import table is mucked up I just find it easier to work with this way. After making any necessary changes with a hex editor you can always rebuild the PE file to get rid of excess padding and reduce its size.
I usually start by noting the Size of Image of the file with PEditor, then when I find the OEP and the place to dump use
/DUMP [image base] [image size] [c:\filename]
[image base] is usually 400000 for exe files, but for your dll would be 10000000 I guess. [image size] is the size you saw with PEditor.
Then you need to change the OEP and code characteristics of the 1st section to E0000020 (usually). And most importantly, use the dumpfixer option of PEditor to make the ROff=VOff and RSize=VSize. If everything went well this last step will now show the icon of the file properly. If the Imports look good you're laughing. If not, you need Revirgin
A basic /PEDUMP would be
/PEDUMP [image base] [OEP] [c:\filename]
where [OEP] is a Relative value without the image base added. i.e. if you find the OEP is 401234 then you use 1234 here.
Hope this helps,
Kayaker