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[Rich <679512@xxxxxxxxxxxxxxxxxx>]

This bug is still there. I regularly encounter it since 2009.
I have experienced the issue on all 3 computers that I use:

Windows 7 64 bit running 32 bit and 64bit Hugin (installer not self compiled). All versions from 2009 to 2010.4.0
Hardware is 4GB ram 400GB free on hard disk. 200GB free on scratch disk.

Laptop running windows XP 32 bit. 4GB RAM, 20GB Hard Disk free, no
separate scratch disk. All 2010 versions of Hugin (installer version) I
did not try any earlier version on this computer.

Windows 7 64 bit running 64bit Hugin (installer version 2010.4.0) 8GB RAM. 900GB free on hard disk, 16GB USB memory confgured as Readyboost cache.
On this computer, when the stich fails, the error report includes the % of memory used. This has never been more than 30%.

A related problem is that enblend and enfuse do not use the specified TMPDIR (or it is not passed to them in the make file).
I have tried manually setting it in the registry, a system variable, the command line, the make files, the PTO files, and of course in Hugin preferences. I was unsuccessful with all attempts.
TMPDIR worked on one early 2010 release but, not before or since.

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https://bugs.launchpad.net/bugs/679512

Title:
  Enblend fails from Hugin, works from cmd line

Status in Hugin - Panorama Tools GUI:
  Fix Released

Bug description:
  This bug has actually been reported a number of times, but closed out
  because people assumed it was simply a problem of not enough disk
  space. I have a case that proves this is not the case... and have
  added some information that will hopefully help diagnose the real
  problem.

  My bottom line: Enblend works from command prompt, not from Hugin, and
  I suspect the issue is that Hugin may not be properly setting
  environment variables before launching Enblend.

  ERROR SEEN (during stitching, when directly run by Hugin):
  enblend: info: loading next image: pLTRR0000.tif 1/1
  enblend: info: loading next image: pLTRR0001.tif 1/1

  enblend: an exception occured
  enblend: enblend: unable to create image swap file name.

  enblend: info: remove invalid output image "pLTRR.tif"
  make: *** [pLTRR.tif] Error 1

  HOWEVER: there is no error if the exact command listed in the Hugin
  window is run from command line!

  i.e., I copy the command, open a command prompt, go to the project folder....
           f:
           cd \photos\pLTRR

  ...and paste in the enblend command:
  "C:/apps/photo/Hugin/bin/enblend" --compression LZW -w -f12764x5389 -o "pLTRR.tif" "pLTRR0000.tif" "pLTRR0001.tif" "pLTRR0002.tif" "pLTRR0003.tif" "pLTRR0004.tif" "pLTRR0005.tif" "pLTRR0006.tif" "pLTRR0007.tif" "pLTRR0008.tif" "pLTRR0009.tif" "pLTRR0010.tif" "pLTRR0011.tif" "pLTRR0012.tif" "pLTRR0013.tif" "pLTRR0014.tif" "pLTRR0015.tif" "pLTRR0016.tif" "pLTRR0017.tif" "pLTRR0018.tif" "pLTRR0019.tif" "pLTRR0020.tif" "pLTRR0021.tif" "pLTRR0022.tif" "pLTRR0023.tif" "pLTRR0024.tif" "pLTRR0025.tif" "pLTRR0026.tif" "pLTRR0027.tif" "pLTRR0028.tif" "pLTRR0029.tif" "pLTRR0030.tif" "pLTRR0031.tif" "pLTRR0032.tif" "pLTRR0033.tif" "pLTRR0034.tif" "pLTRR0035.tif" "pLTRR0036.tif" "pLTRR0037.tif" "pLTRR0038.tif" "pLTRR0039.tif" "pLTRR0040.tif" "pLTRR0041.tif" "pLTRR0042.tif" 

  ENVIRONMENT
  WinXP SP3, Hugin 2010.1.0.5161 built by Zoran
  C: drive does NOT have enough space
  F: drive has plenty of space (30+GB free)
  Project is on F:; 
  TMP and TEMP vars point to f:\temp\WinTmp
  Hugin temp setting points to f:\temp\HuginTmp

  SI FILEMON MONITOR LOG shows...
  From the command prompt, Enblend uses F:\temp\WinTmp as it should.
  From within Hugin, Enblend dies without attempting to create a temp file at all!

  THE BIG QUESTION
  What is different between calling Enblend from the command prompt vs from Hugin?

  My strong suspicion: Hugin improperly sets environment variables
  before launching Enblend