'Core Audio Overload' with Halion Symphonic Orchestra

I use a G5 2.5Ghz Quad with 6GB of RAM. I have 59 tracks open on my Autoload that I whittle down during mix time by comping the various instruments and generally never have a problem.
I installed Steinberg's Halion Symphonic Orchestra and have been experiencing Core Audio Overloads frequently since then. Watching the performance, I had 64% of my processor power idle and 1.79GB of RAM free when it last occurred. I'm stumped!
I may be wrong, but I think with that much Idle system resource I should be able to get away with an I/O Buffer size of 512 to avoid latency? It will run fine in 24 bit on 1024 or 16 bit in 512. I used to find the I/O buffer at 64 was enough.
Steinberg are as interested in my query as a monkey reading poetry - the helpline guy even told me he hadn't configured his software properly, so unfortunately could not help. Hilarious. Steinberg have no Genius's apparently.
Halion aside, does anyone else have this problem where system resource seems adequate but Core Audio is still overloading?

Have a look at my post - Core Audio Overload...
Similar problems with the Vienna Instruments - and again, I'm simply stumped. I vaguely remember this happening less with OSX 4.8, but that may be a dream of times gone by when such things didn't seem to frustrate me as much as they do now.
I have everything maxed out on the buffer side and still to no avail. Certainly, when I did a DiskWarrior rebuild it help for a while. My most recent one, however, told me that it couldn't replace my drive because it was too severely damaged. Had to Clone it to keep the repaired version. Running out of places to put all my back-ups.
Am about to re-install entire operating system and Logic and see if that helps. Will return to my post and update it if things do improve.
G5 Dual 2.5 with 8 Gig RAM   Mac OS X (10.4.8)  

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    Message was edited by: J A Bohrer

    When I was on the phone with M-Audio Tech Support (they're quite helpful) we noted the following:
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    Message was edited by: J A Bohrer
    Message was edited by: J A Bohrer

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