So tried that with a fresh full un-install, reinstall and just used FAFCache and FAFModsMaps folder names and same issue.

Correction, I created that folder under the D:\FAF Client*FAF_CACHE* b/c the client initially created it under the default C:\ drive even though I installed it to D:\

I choose a different folder and created that cache folder on D:\

Fresh install of FAF Client v2025.2.1

SCFA is installed via Steam here:
D:\Steam\steamapps\common\Supreme Commander Forged Alliance
FAF Client is installed here:
D:\FAF Client

Error when trying to launch a game or reply:
Client Version: 2025.2.1
Caused by: java.io.IOException: Cannot run program "D:\FAF Client\FAF_Cache\replaydata\bin\ForgedAlliance.exe" (in directory "D:\FAF Client\FAF_Cache\bin"): CreateProcess error=267, The directory name is invalid
at java.base/java.lang.ProcessBuilder.start(ProcessBuilder.java:1170)
at java.base/java.lang.ProcessBuilder.start(ProcessBuilder.java:1089)
at com.faforever.client.fa.ForgedAllianceLaunchService.launch(ForgedAllianceLaunchService.java:161)
... 25 more
Caused by: java.io.IOException: CreateProcess error=267, The directory name is invalid
at java.base/java.lang.ProcessImpl.create(Native Method)
at java.base/java.lang.ProcessImpl.<init>(ProcessImpl.java:500)
at java.base/java.lang.ProcessImpl.start(ProcessImpl.java:159)
at java.base/java.lang.ProcessBuilder.start(ProcessBuilder.java:1126)
... 27 more

File mentioned in error is in that directory:

Here is my FAF Client Settings \ FAF

What am I missing, doing wrong?