This might help in the long run.
Expression Web Dynamic Web Templates Ebook
http://any-expression.com/expression-web/ebooks/expression-web-dwt-ebook.htm
I would use includes within the dwt in an editable area for the menus
Design Time Includes
http://any-expression.com/expression-web/tutorials/insert-include-pages.htm
the crashing was most likely a problem with incorrect code, it can trigger a crash if ew (or fp) can't cope with it.
When wanting to do this type of thing, the best thing to do with your template is to make sure it validates and works correctly before making it a dwt and using it.
You might want to use the following too...pick which ever version you have
Free Setting up Expression Web 2.0 Ebook (NEW)
Free Setting up Expression Web 1.0 Ebook (Revised)
http://any-expression.com/expression-web/ebooks/setting-up-expression-web-ebook.htm
When your ready for a critique and help with the new template come back and let us know.
In making over your site.... apart from making the template then making it a dwt.....what did you do next? I am interested in how people are migrating from fp to ew and the methods they are using. How big is your site, how many pages does it have?
Tina