If the game crashes when you hit 'Deploy', you may have a BattleRecorder file made with another version of FS. For example, I imagine that if you made a recording with the first release of FS, then installed the hotfix, the recording may not work anymore for you unless you revert your FS install to before the hotfix, or perhaps create a copy of FS which you don't patch, solely for playing those recordings.
In short, you need to play the recording with the same mod and mod version you used to record it with. Sad, but true.
"One of the bitches actually gave birth while she was attacking, and her puppies joined in on the carnage."
--the awesomeness that is Boatmurdered.