Gale, the only thing in the _data folder is the .ogg file. When I saved as compressed project, I got the .aup, the __data folder, and an .ogg in the data folder.
If you'd like an uncompressed save, I do have that as well (which includes several .au files in its _data folder) - I'll zip it right now and make it available for you:
http://www.jrssystems.net/audacity_broken_20069.zip
I actually recreated this from scratch:
* opened the original .wav (a capture of a mechanical telephone ringer, from
http://www.freesound.org/samplesViewSingle.php?id=20069 ) in Audacity
* highlighted the first of several "rings" in the file from beginning of that ring to the last moment before the second "ring" began
* used the Zero Crossings tool, then Trim
* save the project
* attempt to export as 16-bit PCM wav - then got the "disk full" error with random garbage in it as described in this thread.
Then I made sure that the project would capture the error for you:
* closed and reopened Audacity
* opened the project saved above
* attempt to export as 16-bit PCM wav - got same "disk full" error, with different random garbage in it
As to version - wups, sorry; I didn't realize this was the Windows-specific subforum! I got here from googling for the error message I had; you may be interested to know for sure that it's not a platform-specific bug - I'm using 1.3.13-beta (Unicode) on Ubuntu 11.04 (Natty) Linux; this is the version that's currently in the Natty repositories. So this should probably get cross-posted (or just plained moved) upstream from this subforum into a cross-platform area, since we've got reports now of people having the issue on Windows
and Linux.