You should check to see whether opendir is sucessful. If it fails, some of your values, such as

$self->{leaf}

will be changed to non-defaults.

Beyond that, you could be having any number of problems with your mason code. Don't be afraid to use <%perl> blocks and $m->print, or to move more code into your <%init> block to make things easier to read. Your reporting component makes my head hurt just looking at it.