I hear the frustration in that, and mine is similar. Toolbars have been a mess since V3 or so, and although V5 stabilized some of the issues, the whole system is like a house of cards, and certain events cause it to come tumbling down. Some of the events are predictable and some are not. For example every time I edit a button - maybe just to update a script or macro - the next time I open Rhino I can be sure that the whole workspace will be messed up, toolbars becoming undocked, etc. However sometimes I just open Rhino - not having edited anything previously - and all the toolbars are gone… (you get “root element is missing”, whatever that means).
The current WIP version is the worst ever for me, it blows up more or less every time I start it. My own workspace isn’t all that complicated either.
Where the fault lies is hard to know. I think simply that as in my “house of cards” analogy above, in putting in all the flexibility that toolbars have today (in Windows Rhino), the system has simply gotten too complex to successfully manage all the possible interactions. (Note in passing that Mac Rhino does not have these problems, but the customizability of the workspace is far more limited… )
One of the primary causes of this is that the Windows Rhino toolbars (macros, images, organization of the bars themselves) are in the rui file, but the locations of where they are located on-screen and which are open are not - that info is in the registry. Correlating the two seems fail under certain conditions.
Another is simply that buttons can be any size (horizontally), toolbars can be docked anywhere, etc. etc. The possible combinations are infinite, and I am guessing that managing this complexity simply fails under certain circumstances. Can it be made to work reliably? I’d like to be optimistic about it, but I’m not unfortunately - based on the fact that if it could have been fixed, it probably would have been a long time ago.
I guess the main thing that saves us is that, aside from hiding and showing standard toolbars, very few people actually customize their workspaces substantially.