I have the same problem (Failed to 'CFileBuilder::AddPCKToEXE'). I'm not sure, but it might be related to the fact I changed the AV a few days ago (migrated from McAffee to Avast). Nothing else has changed (neither the IDE, nor anything in Windows, XP by the way).
This is DBPRo 1.075,
running on Win XP SP3
the editor is DBPro Editor (Synergy), Build Jun 23, 2010.
Of course I tried to disable the AV, to no avail. I also closed the directory, and followed all the above advice, I think (except I did not reinstall the old IDE).
No project compiles anymore. The error happens every time. I'm stuck with an academic research project (no game) which I can no longer modify. This is very bad for me and my students.
Any further idea? Many thanks.
Roland Maurer
FPSE, University of Geneva, Switzerland