Well, since I didn't try all that myself, I don't know how much Rob has already checked and how much not.
But he has some experience with scripts (albeit no C++ knowledge) and all the config stuff that's involved with server/client problems, mods and bots. So I don't think he has just forgotten to define a max_bots limit lower than the max. number of players. And if he did, I'll slap him!
Do I understand you correctly: There's other code that refers to the way the podbot dll processes the podbot.cfg? Yes, that may be...
Oh, and btw, how do you check if the max_bots entry is even checked on server startup? Is there some tool or function that monitors and logs all those cfg entries that are checked when a game is opened?
Man, I feel so stupid 'cause I don't know sh*t about all that scripting and coding stuff...