Huge binary file size difference LV 6.1 to LV 8.2

I have an application that was first developed under LabVIEW 4.2 and has been periodically upgraded as necessary.  It is normally run as a built application so LabVIEW version changes only come in when something in the application has to be changed.  That occasion occurred and we changed from LabVIEW 6.1 to LabVIEW 8.2 for the build environment.  No changes were made to any of the file handling vis (other than what LabVIEW did in the conversion, which I didn't check at all).
The problem is that this application writes a large structure (4320 elements in each of 13 single-precision variables) into a binary file once a day.  When I started the new version of the application the size of the files went from 242956 bytes to 775334 bytes.
The vi to read these files still works for the old files as well as the new files and a set of C routines that I use to read the files seems to also work correctly with the new files - at least the data looks like it is supposed to when it is plotted.
The change in file size is a concern since this application is supposed to keep writing these files every day for many years into the future.
Is there any known way to return to the original behavior with the smaller files?

Hi Bryan,
you say: "all changes are made with rotates and insert elements to prefent the arrays from growing"!
You should use "replace array elements" to prevent array growth!!! Please check this with your application!
Best regards,
GerdW
CLAD, using 2009SP1 + LV2011SP1 + LV2014SP1 on WinXP+Win7+cRIO
Kudos are welcome

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