FCP7.03 hangs/freezes while loading project

Question

I have a Final Cut project file for this feature film I've been working on forever. The project has stopped opening. FCP freezes immediately after the 'offline files' dialogue box. (doesn't matter whether I reconnect media or not.) It thinks for a second, then spinning wheel of death for 5 minutes, then it crashes. I get a KGCore error, which FCS Maintenance interprets as 'out of memory.' Obviously this error isn't the cause, but a symptom.
I just got my computer back from the shop, with leopard 10.5.x. After I had installed all my applications / plugins, something happened, where from that point on I'd get the crash I just described. I troubleshot all the applications, plugins, etc. Uninstalled everything and reinstalled it one at a time. I was able to open the project once after a fresh FCP install, then when I tried to open the same project again seconds later, it froze again with the same problem. Then the same crash every time. I updated FCS, and the first time I tried to open the project it worked fine. Seconds later when I tried to replicate the result, I got the exact same crash. From that point on, the project crashed every time. I ran MemTest and it came out good. Also, last week I had my harddrive, superdrive, battery and screen replaced, and everything else passed the Apple Tech's inspection, so I am confident this is not a hardware issue.
So I reformatted the computer -> 10.6.4. I reinstalled FCS3 and CS4 and Magic Bullet looks for FCP & AE. Everything worked perfectly for 3 days. Then last night I installed Automatic Duck Free XML Exporter [FCP] and this afternoon I installed Automatic Duck Pro Import AE [AE]. Now I suddenly I can't open the FCP project again. Exact same error. Freezes immediately after the offline files dialogue box every time. I am able to open other FCP projects though.
Today I tried uninstalling the Free XML exporter, uninstalling Pro Import AE, trashing my preferences, repairing disc permissions, setting my scratch discs to external drives, and I uninstalled and reinstalled CS4 and FCS3 without any plugins. After the fresh install, Final Cut opened the project perfectly the first time, and then gave me exact same crash every subsequent time I opened the project.
I talked to tech support at automatic duck and the guy said the only file that could possibly affect FCP is the xml exporter bundle in final cut pro plugins. It made sense to me that that was the problem, but at this point I've not only uninstalled that plugin to no avail, but I've uninstalled and reinstalled CS4 and FCS3 too, so I'm thinking its something bigger than that.
I can't wrap my head around whats going on. I'd be more than happy to reformat the machine again as long as I know it will work afterwards. I just can't spend days working on this only to have it implode right afterwards.

Answer 1

I have not tried exporting xmls for each sequence. Its a good last resort for sure, but the thing is that this project is huge. Including the sequence backups for my rough cut and fine cut (which I really don't need), there's got to be 600+ sequences.
I can't figure out how to post attachments here, so I'm including a segment of the 3 crash logs my machine's generated since the last reformat. Please advise on the protocol for posting crash logs. Thanks.
Xx Crash 1 xX
PlugIn Path: /Applications/Final Cut Pro.app/Contents/Frameworks/KGCore.framework/Versions/A/KGCore
PlugIn Identifier: KGCore
PlugIn Version: ??? (???)
Date/Time: 2010-10-06 01:51:38.461 -0700
OS Version: Mac OS X 10.6.4 (10F569)
Report Version: 6
Interval Since Last Report: 2831 sec
Crashes Since Last Report: 1
Per-App Interval Since Last Report: 731 sec
Per-App Crashes Since Last Report: 1
Anonymous UUID: 2967230C-64E1-4949-9579-C1EEEFB884E0
Exception Type: EXCBADACCESS (SIGBUS)
Exception Codes: KERNPROTECTIONFAILURE at 0x0000000000000004
Crashed Thread: 0 Dispatch queue: com.apple.main-thread
Xx Crash 2 xX
PlugIn Path: /Applications/Final Cut Pro.app/Contents/Frameworks/KGCore.framework/Versions/A/KGCore
PlugIn Identifier: KGCore
PlugIn Version: ??? (???)
Date/Time: 2010-10-06 02:01:03.255 -0700
OS Version: Mac OS X 10.6.4 (10F569)
Report Version: 6
Interval Since Last Report: 558 sec
Crashes Since Last Report: 1
Per-App Interval Since Last Report: 504 sec
Per-App Crashes Since Last Report: 1
Anonymous UUID: 2967230C-64E1-4949-9579-C1EEEFB884E0
Exception Type: EXCBADACCESS (SIGBUS)
Exception Codes: KERNPROTECTIONFAILURE at 0x0000000000000004
Crashed Thread: 0 Dispatch queue: com.apple.main-thread
Xx Crash 3 xX
Date/Time: 2010-10-06 02:29:19.260 -0700
OS Version: Mac OS X 10.6.4 (10F569)
Report Version: 6
Exception Type: EXCBADACCESS (SIGBUS)
Exception Codes: KERNPROTECTIONFAILURE at 0x0000000000000000
Crashed Thread: 0 Dispatch queue: com.apple.main-thread