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And as I already mentioned before you should find out the reason why your first launch fails. Your first suspect is pDlg->Create. Please debug it through.

And do us a great favor, please stop...

Attaching a debugger at startup
Debugging Process Startup

The fact that breakpoint appears inactive, and loading dll does not result in breakpoint hit makes me think that you have attached to process other than the one that actually loads your DLL. It's...

You have to learn copying CallStack as text.

And as long as the stack shows that InitInstance is executed within DllMain, you must not use DoModal in this context, as the latter blocks thread...

The word "probably" must be eliminated from engineer's vocabulary. To accomplish your job you have to understand your solution. You have to find out why "restart run" works, but first run does not....

No. In OnClose() handler I believe. Of course you add ON_WM_CLOSE() to message map and send WM_CLOSE on OK or Cancel.

You just add to your dialog class this virtual member function:



void...

BTW, creating window in C++ constructor is a bad style in MFC.

Well, except the fact that you go with technology you are not familiar with... These are two typical snippets for dialogs:
1.

BOOL CPixie3_GUIApp::InitInstance()
{
CWinApp::InitInstance();...

John Robbins, Debugging Applications
Jeff Prosise, Programming Windows with MFC

Additional reading:
Shepherd, Wingo, Programming Microsoft Visual C++
Mickey Williams, Programming Microsoft...

You'd better believe that. Or, which is even better, read some good book on debugging in Windows. :) This DLL debug is kinda trivial: you Attach To Process of your "external CAD tool" and set a...