You should try to minimize the number of problems. Hiding an image file
before you open the .pto may show some bug but I think you want to solve
other problems first, right? Apart from that this should be filed as
another bug.

I saw a remark that you try to work with grayscale TIFFs. Please convert
those to RGB (this won't degrade the image quality) for the libraries
used by Hugin don't  work with grayscale.

Now make sure your file names (images as well as the pto) are named properly 
and contain no special characters or blanks, but have a proper extension like 
.tif
Also make sure that the complete path to the project files contains no special 
characters so the tools used by Hugin don't run into problems while trying to 
access your images. 

Make sure no other copies (e.g. older versions) of hugin are on your
Mac.

Now can you please try two different ways to open your .pto project file: 
- double click the project
- Open Hugin and PTBatcherGUI, and from inside Hugin use the "open file..." 
dialog.

Does it work now?

BTW I can test on 10.6.8, my projects work without problems so there
should be a solution for you.

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https://bugs.launchpad.net/bugs/1065780

Title:
  Hugin crashes on opening pto file (OS X)

Status in Hugin - Panorama Tools GUI:
  New

Bug description:
  
  Hugin crashes from time to time on opening a pto file. It seems to hapen more 
often when other programs are open in the background.
  The same pto file can open 10 times without a problem and then 4 times cause 
Hugin to crash.

  Hugin 2011.4.0 (Mac)
  OS X 10.6.8
  iMac7,1, Intel Core 2 Duo, 2.4 GHz, 4 GB
  Activity monitor: page-outs: 0 bytes, free memory 1.95 GB
  pto file with 2 or 4 TIFF images, 16 bit gray, 717 x 2706, 3.9 MB

  
  Exception Type:  EXC_CRASH (SIGABRT)
  Exception Codes: 0x0000000000000000, 0x0000000000000000
  Crashed Thread:  0  Dispatch queue: com.apple.main-thread

  Application Specific Information:
  abort() called

  Thread 0 Crashed:  Dispatch queue: com.apple.main-thread
  0   libSystem.B.dylib                 0x922a4c5a __kill + 10
  1   libSystem.B.dylib                 0x922a4c4c kill$UNIX2003 + 32
  2   libSystem.B.dylib                 0x923375a5 raise + 26
  3   libSystem.B.dylib                 0x9234d6e4 abort + 93
  4   net.sourceforge.hugin.Hugin       0x001b877d celeste::SafeAbs(int) + 125
  5   net.sourceforge.hugin.Hugin       0x00039428 
boost::shared_ptr<HuginBase::ImageCache::Entry>::operator->() const + 56
  6   net.sourceforge.hugin.base_wx     0x011650a7 
HuginBase::ImageCache::postEvent(boost::shared_ptr<HuginBase::ImageCache::Request>,
 boost::shared_ptr<HuginBase::ImageCache::Entry>) + 183
  7   net.sourceforge.hugin.Hugin       0x0000fa95 
huginApp::relayImageLoaded(ImageReadyEvent&) + 85
  8   libwx_macu-2.8.0.7.0.dylib        0x005dbbb2 
wxEvtHandler::ProcessEventIfMatches(wxEventTableEntryBase const&, 
wxEvtHandler*, wxEvent&) + 114

  In Console:
  12-10-12 03:00:00     [0x0-0x90090].net.sourceforge.hugin.Hugin[958]  
MainFrame::RestoreLayoutOnNextResize()
  12-10-12 03:00:54     [0x0-0x90090].net.sourceforge.hugin.Hugin[958]  Number 
of images 4
  12-10-12 03:00:54     [0x0-0x90090].net.sourceforge.hugin.Hugin[958]  
ContractViolation: 
  12-10-12 03:00:54     [0x0-0x90090].net.sourceforge.hugin.Hugin[958]  
Precondition violation!
  12-10-12 03:00:54     [0x0-0x90090].net.sourceforge.hugin.Hugin[958]  Unable 
to open file ''.
  12-10-12 03:00:54     [0x0-0x90090].net.sourceforge.hugin.Hugin[958]  
(/Users/Shared/development/hugin_related/hugin-2011.4.0/mac/../src/foreign/vigra/vigra_impex/codecman:206)
  12-10-12 03:00:54     [0x0-0x90090].net.sourceforge.hugin.Hugin[958]  ERROR: 
03:00:54.104600 
(/Users/Shared/development/hugin_related/hugin-2011.4.0/mac/../src/hugin_base/huginapp/ImageCache.cpp:658)
 loadImageSafely(): Error during image reading: 
  12-10-12 03:00:54     [0x0-0x90090].net.sourceforge.hugin.Hugin[958]  
Precondition violation!
  12-10-12 03:00:54     [0x0-0x90090].net.sourceforge.hugin.Hugin[958]  Unable 
to open file ''.
  12-10-12 03:00:54     [0x0-0x90090].net.sourceforge.hugin.Hugin[958]  
(/Users/Shared/development/hugin_related/hugin-2011.4.0/mac/../src/foreign/vigra/vigra_impex/codecman:206)
  12-10-12 03:00:54     [0x0-0x90090].net.sourceforge.hugin.Hugin[958]  
/Users/Shared/development/hugin_related/ExternalPrograms/3way-repository/include/boost/smart_ptr/shared_ptr.hpp:418:
 failed assertion `px != 0'
  12-10-12 03:00:54     com.apple.launchd.peruser.502[100]      
([0x0-0x90090].net.sourceforge.hugin.Hugin[958]) Job appears to have crashed: 
Abort trap
  12-10-12 03:00:55     ReportCrash[966]        Saved crash report for 
Hugin[958] version 2011.4.0 (cf9be9344356) to 
/Users/Willeke/Library/Logs/DiagnosticReports/Hugin_2012-10-12-030055_imac-van-willeke.crash

  Also from Console, another attempt, didn't crash:
  12-10-12 01:24:45     [0x0-0x3a03a].net.sourceforge.hugin.Hugin[410]  ERROR: 
01:24:45.271502 
(/Users/Shared/development/hugin_related/hugin-2011.4.0/mac/../src/hugin_base/huginapp/ImageCache.cpp:934)
 loadSafely(): Please set 
HuginBase::ImageCache::getInstance().asyncLoadCompleteSignal to handle 
asynchronous image loads.

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