I recently flashed Das BAMF RC4.9 and everything was fine. I went into toolkit and tried to change font. It told me that after download it would reboot. After it downloaded it turned off and started at HTC splash screen and it stays there, nothing else happens. When I try to power on with volume key it automatically boots in HBOOT and wont let me toggle any other option. I asks if I want to apply update for radio v2 and another file, then it asks to press power to reboot and still hangs at HTC splash screen. Anyone out there know how to fix this?
This is a known issue right now as it's widely believed that the servers containing the fonts, bootscreen animations and splash screens is down. Thus, when you try to select a new one, the phone doesn't actually download anything new and reboots like it did (causing problems.) Unfortunately, it seems the only way to fix this problem is to boot the phone into hboot/recovery and get one of your backups (hopefully you did one at some point) or reflash the rom entirely and start fresh.
Once you accomplish that, I would go here:
[MODS] BAMF Sense 3.0 Extras...It's Been A Long Time Coming [08.05] UPDATE #12
And there's a section where you can physically download the font.zip you want (although there are less to choose from) and flash it via recovery. There's also a lot of other mods to choose from (custom lockscreen rings, status bar changes, etc.). Hope this helped.
EDIT: For removing the PG05IMG file, I would recommend scotty's method. But there is another technique that does not require a card reader that I've used with success, but it's a little less "safe"
Turn phone off
Remove battery
Remove SD card
Replace battery
Plug USB charger into phone
HBOOT phone
Select USB Power option (can't remember the specific name)
**This should now allow you to remove the battery without the phone turning off.
Remove the battery, reinsert the SD card, replace battery and boot into recovery mode to access backups or reflash the rom