Ok so this is my problem:

I took the default map, changed the terrain sized, moved the CPs, did a little bit of work, munged etc. and the rebels fall out of the world when they spawn.

It was only the default CP, after a few changes I decided to just make a whole new CP, but the same thing happens, when the rebels spawn it immeadiatley just says "BREAKDOWN DIED" and goes back to the select screen.

I can't go much in depthon the actual map, it's a large secret project, but I was wondering if anyone has an idea why they fall out of the world.

check your spawn path

I did, and I made sure it was above the ground

It could be that your map size causes the objects and terrian to be out of wack. What is your map size?

900 by 900. Don't ask.

Well that looks like that's it. It has to be a double: 128-254-512-1024 and so on.

I tried making it 800 by 1600, but it still doesn't work. Hmm

That's not how it works. You need to make the map size a power of two (2 by 2, 4 by 4, 8 by 8, 16 by 16, and upward).

Ohh, thank you, I will report back soon