Try:
using \letterhash instead of \#
or
\startasciimode
\def \FrontMatterTitle {
\startreusableMPgraphic{frontmattertitle:\overlaywidth:\overlayheight}
matter_paper_width := 4.25in;
matter_paper_height := 6.875in;
front_left_margin := 0.388888888889in;
top_margin := 0.347222222222in;
draw (0, 0)--(matter_paper_width, matter_paper_height)
withpen pencircle scaled 1bp withcolor white;
picture titleText;
%% == HERE IS THE SOURCE OF THE PROBLEM ==
titleText := btex {\vbox{\hsize 2.72916666667in \baselineskip 38.0pt
\setupalign[flushleft,hyphenated,verytolerant]
\TitleFont THE BEGINNINGS OF #BOOM}} etex;
%%%%%% NOTE I changed \# to # and % to %%
labeloffset := 0bp;
label.lrt(titleText, (front_left_margin,
matter_paper_height - top_margin));
\stopreusableMPgraphic
\reuseMPgraphic{frontmattertitle:\overlaywidth:\overlayheight}
}
\stopasciimode
You can also use \framed[width=2.73in,
foregroundstyle={\TitleFont\setupinterlinespace[38pt],
align={flushleft, ....}]{The ....} instead of explicit \vbox.
Aditya
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