How to properly convert from LV2009f3 to LV8.5.1

Hello,
I have a fairly large project for an AOI which was initially developed in LV8.2 and later ported up to v8.5.
The project has a Windows and an FPGA target and relies heavily on NI Vision and IMAQ for the inspection parts of the application.
I recently decided to jump to LV 2009f3 for the new generation of the machines. I added a lot of functionality and minor bug fixes and prepared the code to work on various generations of the machine by using Conditional Diagram Disable structures and Conditional Disable Symbols.
The problem is that I need to go back to v8.5 to compile the executable and make sure that it will work on the older systems with LV and Vision 8.5 runtimes.
First I tried to save the entire project to version 8.5 but failed after multiple attempts: I always get a 'Memory Full' error with the same VI, which is the first in the project that accesses Vision functions. When I save the projecto to version 8.6 this error doesn't occur.
I concluded that this first situation is related to saving from 2009 to 8.5 when you use Vision functions.
I was able to get to version 8.5 by saving the project from version 8.6 to 8.5. The fact that you need an intermediate step is apparently well known in the forums as a bug in LV2009.
But my real problems are starting now. I currently have all the files saved as version 8.5. NOTE: the project could not be saved, but I managed to recover a version 8.5 project from my old code and used that, because the file structures were kept intact.
My current issues are with the VI's that call Vision and FPGA functions/nodes. They will ALWAYS crash: the vision related VI's crash during loading with the infamous 'Memory Full' error, while the FPGA related VI's crash during loading with the 'FPSANE.CPP' error. The 'Memory Full' error is related to nivision.dll.
I'm unable to open the VI's so I'm not sure what to do now.
Is there any way to "properly" save such a large project from 2009 to LV8.5? What toolkits and/or picture versions should I choose when LV asks me during the 'save for previous' operation? Has anyone experienced the same issues? How did you solve them?
Please help me. I don't know what to do.
On a side note, the VI's for the FPGA target opened without any trouble and I was able to compile the VI's into a bitfile without any hassle. Why so many problems with the Host target VI's?
Regards,
Habil Silva
TESTWISE
Portugal

Hi James,
Thank you for your reply.
Regarding your suggestion, I've been trying just that. I have a dual boot on my machine with Win7 + LV 2009f3 and WinXP + LV 8.5.1
Inside Win7 I have a WinXP virtual machine that runs LV 8.6. So in fact it's just like I used 3 different machines to do the porting, so that should not be the issue.
I have also created a virtual machine from the original WinXP + LV 2009 installation on the AOI machine to be able to continue developing on my laptop without having the typical file paths and add-on/driver version issues that one usually has in these situations. So I'm all set regarding this.
I'm only having these issues because I want to go back to LV 8.5.1 to do maintenance on an older machine.
Another valuable piece of information is that the VI are not really corrupted. They will open fine in LV 8.6 or 2009. Only not in 8.5.1...
What I'm going to try now is to open the project in a clean install of LV 8.5.1 but without the Vision and FPGA modules installed.
Maybe this way instead of the before mentioned errors and crashes, LV will only complain about missing VI and CTLs.
This will take some time so in the meantime I really appreciate more help.
Best regards,
Habil
TESTWISE

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