I did it as follows: After starting the software I opened the "Options" menu. On the following screen I clicked on "Select Aircraft" in the upper left corner. On the next screen I selected an aircraft in "Select aircraft for this flight" in the uper left corner and a checklist in "Select checklist for this aircraft" in the upper right corner. Having done that I clicked on "Safe profile" in the lower left corner and gave it a new name. That's all I did.
I did it with my own created aircraft and checklist files. Just now I did the same with original data (King Air 350 for aircraft and checklist) but the result was again a 3000KB big XXX.pro file.
BTW, I hope you are wrong with your HD clue but I will check it and safe my data immediately
