The ns_uuencode patch in the OpenACS distribution is indeed broken, and I think it could cause the crash you are seeing. I just submitted patch #698741 at SourceForge four days ago so it definitely isn't in any version of AOLserver. You shouldn't need to apply it though, as OpenACS works around the issue in Tcl if the patch is not applied. (As opposed to an applied but broken patch.)
If you really despise Tcl, don't like patching things, or want a simple out-of-the-box solution, then the OpenACS toolkit probably isn't a good match for you. It includes over 170,000 lines of Tcl alone and has all the complexity that implies.