Before i start i'd just like to say that i have no clue if this will work for anyone else, it could purely be my phone and a fix for me, so i'm sorry if i've given you false hope but i know there's a lot of Fallout lovers out there who are facing the same problem and if there's a 1% chance this works for you then that'd make me happy!
Anyway.. I'm playing using an iPhone 4s and as we all know the game doesn't run too smoothly on older iPhones and iPads. I've been desperately trying out many different ways to fix my problem and in the end i ended up just giving up and playing a vault that had only a few dwellers (I still have to play it somehow for the love of Fallout!)
UNTIL.. One day i went to try my vault that crashes upon opening and i accidentally tapped the home button, i quickly re-opened the app because i knew it'd still be in loading phase and wouldn't restart the game, and whaddya know?! It loaded, my vault of 60+ dwellers finally loaded to my great surprise. I thought it was just by pure chance that this happened but i thought i'd just test it again.. I closed my game, tried re-loading the vault normally without hitting the home button and it crashed, i tried loading it again but this time as soon as i hit "load Vault 800" i tapped the home button and quickly opened the app back up.. and whaddya know?! It worked again.. My vault loaded successfully.
So.. I'd like for you guys who are having problems to try this. It may seem almost too simple but it's worth a try.. As soon as you hit "Load vault".. hit your home button (Do not completely shut down the app) and load the app again so it goes back to the vault loading screen.
This may sound like absolute BS, and again, i apologize if it doesn't work for you. But this really does work for me, i am able to now play a 65+ dweller vault pretty well on my iPhone 4s, every now and then it does crash upon loading but i just repeat the same sequence and it works.