Help! PrPro 5.5.2 and nVidia 285.62 on GTX 285

Question

Ok, I had posted about this about a month ago over in the main forum, and thought I had solved the problem, but it's back. Unfortunately I can't find my original post to resurrect it, as Jive seems to have wiped my post history beyond two weeks ago... :-(
Anyway, I bought PrPro 5.5 to work with RED Epic footage, and installed it alongside my 5.0.3 on Win 7x64 Ultimate. I ran all updates (5.5.2), and then on my first startup got the message that I wouldn't have CUDA support since there was no CUDA enabled card installed. I knew that wasn't right cause I used CUDA all the time in 5.0.3, so I checked and found my drivers were significantly out of date. I updated my nVidia drivers from nVidia's site, rebooted, and relaunched PrPro. Everything worked great. Until I had to export my first video. During export I consistently got an nVidia driver error, saying that my system resources didn't match what was required by the program (something about it couldn't get small enough packages for the video card to process), and it had to close. Closing the nVidia driver error box also force quit PrPro. I discovered that by running without CUDA I had no issues and could successfully export my video. However, I can't afford the time to run without CUDA as it significantly speeds up the processing time, especially with multiple layers of Epic footage.
So ultimately I did a complete wipe and reinstall of the entire system, starting with the most recent non-beta drivers available for the nVidia card, and put only 5.5 on the system and fully updated to 5.5.2. It recognized my CUDA card and there were no issues. I've worked off and on (very light work over Christmas) until today when I dug back into my big Epic project and started doing some basic scaling and speed adjustments on some clips, and some primary CC with the RGB CC and Three-Way CC. I frequently get the same nVidia error message that I had gotten before I did the wipe and re-install, and it's killing my workflow and productivity. I turned CUDA back off again this afternoon to get this one timeline finished and exported, but I really need it back.
What changed about CUDA support between 5.0.3 and 5.5.2 that has screwed things up with my GTX 285? And what do I need to do to fix things and get them back up and running? Before the wipe and reinstall I had tried multiple versions of the nVidia drivers, incluidng rolling back as far as I could go and keep CUDA support, and the new beta drivers that Ann and others had recommended. Unfortunately purchasing a newer graphics card probably isn't an option since I've already spent over $2300 in the last couple months on hardware and software upgrades.
As a refresher, my other system specs are as follows:
Intel Core i7-920 2.67GHz (no overclock)
12GB RAM
250GB SATA OS/Programs
500GB SATA Graphics/Pictures/Other stuff/Pagefile
3-disk SATA RAID-5 2TB Video Project Files
4-disk SATA RAID-5 8TB Video Data Files (PCIe RAID card)
1TB SATA Video Export/Encore Project files
4TB eSATA Data Backup (not currently in use)
400GB eSATA Project Backup (not currently in use)
Here is the additional spec information from my GTX285 card, pulled from the nVidia system information dialog:
Driver version: 285.62
DirectX Support: 10
DirectX Runtime Version: 11
CUDA Cores: 240
Graphics Clock: 648 MHz
Processor Clock: 1476MHz
Memory Clock 1242MHz (2484 MHz data rate)
Memory interface: 512-bit
Total available graphics memory: 4095MB
Dedicated video memory: 1024MB GDDR3
System video memory: 0MB
Shared system memory: 3071MB
Video BIOS version: 62.0.58.00.03
IRQ: 30
BUS: PCI Express x16 Gen2

Answer 1

Ok.... I just turned CUDA back on and ran it as hard as I could (Secondary CC, etc.) to make it crash again. Here's the screenshot of the error message:
And here's the detailed info from the nVidia page referenced in the error message:
OpenGL message "hardware does not meet minimum specifications"
I have seen this Event Log Message:
Your hardware configuration does not meet minimum specifications needed to run the application. The application must close.
What does it mean?
The most common cause for this issue is that the application was unable to continue due to hardware limitations. The workload the application sent to the Graphics Card could not be broken into small enough pieces to be processed.
How can this be fixed?
Verify you are running the most recent driver for your application. Drivers certified by Professional Software vendors can be found herehttp://www.nvidia.com/page/partner_certified_drivers.html. If you application is not listed, install the most recent driver for your graphics board from www.nvidia.com/drivers. You should also check with your application provider for any updates or patches to your application.
You can also try manipulating a smaller image as you may be running out of video memory with extremely large images.  If none of these work, you likely need a more powerful Graphics Card to handle this application.
If you are certain that your graphics card meets the application hardware requirements and none of the above suggestions solve the problem, please file a support request here by clicking on "Ask a Question" near the top of this page. Please make sure to correct enter the operating system, the NVIDIA driver version, the application name and version, graphics board maker and model, along with the steps which were taken to make this issue appear.
Also, I've noticed that it generally happens ONLY after PrPro has eaten up more than 4GB of system memory (PrPro memory configuration is set to Performance and to allow PrPro access to 8GB of my 12GB of system memory):
Does this info help anyone at all?