Lightroom 2 Issue

I have been using lightroom 2 for about a month now, and I love it. So much you can do and workflow has increased dramatically. I am having a periodic issue though. Here is what happening:

I import my .RAW files to Lightroom
Then I go through them and "reject" or "flag"
Then I turn on the flag filter

Then I go through each photo 1 by one and edit. Usually involves exposure mask, skin softening mask, vignetting, and other tweaks. If the image is similar to the the previous I hit "previous" to carry the edit setting over.

Once I am finished I "Export" them as JPEGS to specific folder.

Then I upload them to my SMUGMUG site.

Sounds ok right? Well there are always a few files that will not upload because they are "Invalid" or something. I can take those "Invalid" files and open them in Photoshop 7.0, but I can "Save" them at all. It says "Could not save "filename" due to program error.

Anyone else had an issue with this?

That is pretty odd and nothing jumps out in your workflow to cause this. Hopefully Victoria or another expert will have an idea.

What happens if you take one of the originals that did not save out correctly and then "edit in external app" like photoshop and then save it out as a JPG that way? Photoshop can do it, right, just not LR?

What version LR2?

There used to be a bug with LR2 and PSCS2 and localised adjustments that gave ""Could not save "filename" due to program error." in PS. But AFAIK that's fixed.

"Save for web" did work in that case (at least, for me)