The error reported by the OP regards author_sort. The contents of Author is not relevant. Specifically, the error message says that author_sort is empty, meaning author_sort[0] is undefined, which calibre is reporting. This is correct behavior -- calibre is reporting the error that the template asks for information that is not available. There is no "obvious bug" here.
The next question is "how did author_sort become empty?" There are several ways to do this, including the "manage authors" dialog and metadata edit. Apparently it was possible to do this during import sometime in the past, but I think not since middle 2010. Starson17 and I have tried several ways to create a book with an empty author_sort and have not been able to do it.
If someone has a way to enter a new author or import a new book and have the author_sort remain empty, I would like to see it. The author name must not exist before the book is imported/changed. If the author already exists, then the test is flawed because that author might already have a stored empty author_sort value.
@goingdown: you don't say which version of calibre you are using. It would be useful to know whether or not the authors Unknown and unknown both simultaneously exist and if so whether the author_sort values for these two authors are defined, something you can see using "manage authors" (right-click on an author in the tag browser and choose "manage authors"). It also would be useful to know what the author_sort value is for a failing book after you make the change, and whether calibre considers that value as correct (not pink) -- both of these can be seen using edit metadata.
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