CHM Compiled Help files all give – NOT FOUND error

The "bitness" of a machine has nothing to do with this process. Bitness refers to the amount of memory a processor can address. 32 bit machines can address 4GB of memory, far more than you need for this. And even, if you needed more, the machine would simply page memory. Which would slow the process down, but not prevent it from working.

I just downloaded and installed Microsoft's HTML Help Workshop and was able to decompile and recompile a handful of 15+ MB CHM files, including a 25 MB one. The problem is most likely something on the machine that is causing an issue, perhaps a virus scanner. Try disabling any virus scanners before you compile. Have you tried compiling the CHMs on a different machine? And why do you think you are running out of memory?

The recommended way to test using IE 6 on a Windows 7 PC is to run a Windows XP virtual machine with IE 6. You can download this (Windows_XP_IE6.exe) for free from Microsoft at: http://www.microsoft.com/download/en/details.aspx?id=11575