How to resolve if Repackager stopped working ?
Answer Chosen by the Author
Build the IRP into an ISM first, them create the MSI from that.
I found the same issue you had years ago, it never used to handle massive reg keys in the capture. If you wanted to check if this is your cause...
Take a COPY of the Standard.nir. keep it somewhere safe. Then take out pretty much everything and leave just one or two keys, just as a test.
Try building the ISM. If it does work, you know you have an issue with the reg keys. Excluding the reg keys in the IRP does not work. You have to actually remove the sections of the registry in the NIR file.
If it still doesnt work, then you likely have a file issue.
Since you mentioned that you have a failure when trying ALL apps, I doubt its a file thing.
But I have seen in the past when an app has a bad file size or too many languages and InstallShield doesnt like it. That's actually easy to discover, as the ISM will be built, but it will be missing a heap of files. Just check what was the last file added to the ISM, then next file in the INC is the one that has the issue. Remove that line, rebuild the project, then add the single file later on.