If the crash occurs as soon as you select the new Hurricane, or as soon as you click "Fly Now", or as soon as you try to save the mission, then try editing the mission using Notepad to replace the missing planes with ones in your livery.

If the crash occurs when you click on "Advanced Info" or when attempting to look at the map while in the mission then the problem is probably a conflict in the runway ID numbering system between what's in the converted missions and what's in your airbases.dat file.

Personally I shy away from CFS1 converted missions and recommend looking for ones written sprcifically for CFS2 or writing your own.

Assuming you have all of the aircraft, ships, and infrastructure that a mission calls for you can fly any mission in the game even if you don't have the airfield scenery installed.  When flying the mission your position is determined by the longitude and latitude written into the mission file, not by the airbase.dat entries. However, just because you can fly the mission doesn't mean it will work right.

If you're flying the mission out of Adak, Alaska but don't have that scenery installed you'll find yourself sitting on the tundra when you should be sitting on a runway.  Additionally, when you warp back to the base to land you may see nothing but bare ground. Another possible glitch is caused when you have one version of an airbase entered in your game but the mission author used a different version of the same base.  In that case you may find yourself sitting inside of a building or in a vacant field a quarter mile from where your base is located.  Again, this is caused by the mission using longitude and latitude to determine your position and his starting position lining up with his scenery, not yours. 

As you mentioned, this becomes a management issue with downloaded missions as you may have to tweak the takeoff and landing positions to get them to fly right for your setup.

The big problem comes when you try to look at the map or go to Advanced Information.  If the runway ID's shown in the mission file don't match the ones in your airbases.dat file you can get a crash.  None of these problems are insurmountable, but you may find that in some cases it is more bother than it's worth to tweak the missions, particularly if it is a very large campaign.

At least two things have happened here:

1. The new Hurricane will not load in the mission and I'll bet it doesn't showup in Free Flight either.   This is because of one, or both of the following.   In the Sound and/or Panel folders of the new Hurricane either the panel.cfg and/or the sound.cfg files are aliasing to an aircraft that is not present in your CFS2/Aircraft folder.  This is probably the only problem you have.

If you don't find the problem there, then one of the files in the Hurricane folder is misnamed.....most probably either the DP or AIR file.   Check those file names.  The AIR, DP and CDP should carry the same name exactly as is defined in the Aircraft.cfg file under the 'sim=' entry.   Also check the Model folder to make sure that the Model.cfg file defines the 'normal=' value as the exact name of the MDL file.  That should fix the Hurricane.

2.  When you replaced the offending Hurricane in MB, the setting 'Takeoff From xxx' at WP1 probably defaulted to 'Turn' or 'Takeoff from Current Point'.  That's why your replacement aircraft wasn't on the runway anymore.   To fix that(and it can happen anytime you change an aircraft in MB) click on WP1 and under the Waypoints Tab, reset the command to 'Takeoff from xxx' (where xxx is the name of the airfield) on the dropdown menu for that WP, because I'll bet it reads 'Turn', or 'Takeoff from Current Point' when you open it.  (You can't just drag WP1 to where you want it and drop it, if it is set to 'Takeoff from Current Point'.  When you set it to 'Takeoff from xxxbasename', the WP will snap into position on the airfield.)   This should fix your mission file.

I hope I have explained all that plainly, and that this will help you salvage your plane and campaign.   Don't give up so easily.  

NOTE: All of Cody's advice is good, and mine depends on his points being checked and correct.  Because a numbered airfield in the Airbases.dat  that doesn't match that of the one in the mission will be fatal.

Ah, yes.   I did misunderstand or misread....been a long day, or I just had a senior moment.   

It probably is an airbases.dat issue.  If by Korea downloads you mean the Fox4 campaigns, we incorporated a very carefully modified 'stock CFS2' airbases.dat file in the downloads...the 'mod' part being the addition of the proper Korean airbases used in the campaigns at the end of the stock file.

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That would be one damned fine thing to have.  A downloadable/printable directory of airfields with a uniform numbering system.   It would go a long way to preventing the airbase.dat file conflicts caused by everyone going his own way.  You may have found yourself a worthy project.