Length limits of Motion?

I've been working on preparations for a rather large DVD project for a month or so now, and I have been experiencing some trouble with exporting from Motion. In total I aim to make 3 DVDs, and I have mapped out the first disc to be about 60 video tracks, 13 motion menus and about 90+ still menus... and thus far my plan has been to export these all from Motion.
About half of the clips I need to make are between 1 and 2 min, and those are working just fine ( aside from client style choices... grrr). But the other half of the clips range from 3 min to as long as 15 min. When I try to export these they fail overnight and result in a file I can't open anywhere (I've sent Apple a lot of error reports lately). Last night an export 'died' rather than failing? Er... well... the resulting file was viewable, but it ended early and the last few frames looked like this:
http://www.flickr.com/photos/12765641@N08/sets/72157624426471397
Just recently I upgraded the graphics card in my Mac Pro from a standard 'NVIDIA GeForce GT 120' to the 'ATI Radeon HD 4870' (as far as I could tell in my research the best card currently available for Motion, best being very near the speed of and less bugie than Nvidia's Quadro FX 4800). Preview frame rates and estimated render times are much improved, but the same renders are crashing overnight...
I am currently considering upgrading the amount of RAM in the machine from 6Gb to 12 or 16 or ? But I found this post and was looking for further insight...
http://discussions.apple.com/message.jspa?messageID=635107
"20 minutes! Holy Frijole! Motion is not made for something this huge. Motion loads everything into memory. 20 x 60 x 30 = 36,000 megabytes - or 36 gigabytes."
Please explain 20(min?) x 60(sec?) x 30(fps?)? is 1 Mb pr frame an actual metric for Motion? so at 6Gb of RAM I should be able to export a 3:30 length clip? (this seems consistent with my lengths of failed and successful exports thus far)
Is there an 'Apple suggested' or 'community known' length recommendation for a Motion Project? If so, does the content complexity or resolution of a project affect this length? (I'm creating the whole thing HD for possible future Blu-Ray authoring, but this project in it's current form will go to standard definition DVD)
Why do I want to export 15 min clips from motion in the first place? My project is a 'Video Textbook' with multiple ways to traverse the content (thus the ridiculous number of menus and tracks). There are 3 components to pretty much every frame in the project. Video or animated still images on the left, text fading in and out on the right summarizing some of the dialogue or Voice over and verbatim transcript for other parts, and at the bottom of the frame a timeline showing the user where they are, progress wise, at all times on the disc. The video I have been given is all poorly shot Green Screen footage, some of it I have been able to squeeze a Key out of, but with a good chunk of it I am just conceding defeat and making it look like a white room on an old TV screen...(Re-Shoot has been begged and pleaded for...) Essentially all the video content have motion effects applied to them, the amount of text would be far to un-wieldy for Final Cut, and the Timeline is all built in Motion as well... far as I can tell, everything capital 'N' need's motion, is there a better way?
....I have conceded at this point that I will probably just have to make some changes to my proposed workflow for this project... But regarding which changes to make, would it help to export each of my three parts individually and then combine them in Final Cut or will the lengths of segments still kill motion even at much less complexity? Or is it the case that I should just export everything in chunks no bigger than 3 min? How else could I get this stuff exported?
Running Motion 4.0.2 and FCP 7.0.2
Any ideas, thoughts or suggestions would be greatly appreciated!
-mjwill

Came in this morning to find Final Cut Pro displaying "Codec Error", so as I was re-checking what codec I was using, Final Cut Crashed...
https://docs.google.com/document/edit?id=1f5jIyrkRyM0WWtHsRRaQMbQz44Wb5utyCsJE77 avGyo&hl=en&authkey=CMnew_gN
I found out that the someone set the default project for this machine to HDV (ew), so I changed it to 1920 X 1080 ProRes, and I'll try again...
I looked in the console and it looks like this (below) had been on repeat for about 2 hours, during my render attempt, it filled the whole scrolling area in the console with about 1/2hrs worth....
7/21/10 7:35:58 PM [0x0-0x23023].com.apple.FinalCutPro[181] Final Cut Pro(181,0xa01eb500) malloc: * mmap(size=268439552) failed (error code=12)
7/21/10 7:35:58 PM [0x0-0x23023].com.apple.FinalCutPro[181] * error: can't allocate region
7/21/10 7:35:58 PM [0x0-0x23023].com.apple.FinalCutPro[181] * set a breakpoint in mallocerrorbreak to debug
7/21/10 7:35:58 PM [0x0-0x23023].com.apple.FinalCutPro[181] Final Cut Pro(181,0xa01eb500) malloc: * mmap(size=268439552) failed (error code=12)
7/21/10 7:35:58 PM [0x0-0x23023].com.apple.FinalCutPro[181] * error: can't allocate region
7/21/10 7:35:58 PM [0x0-0x23023].com.apple.FinalCutPro[181] * set a breakpoint in mallocerrorbreak to debug
7/21/10 7:35:58 PM [0x0-0x23023].com.apple.FinalCutPro[181] Final Cut Pro(181,0xa01eb500) malloc: * mmap(size=268439552) failed (error code=12)
7/21/10 7:35:58 PM [0x0-0x23023].com.apple.FinalCutPro[181] * error: can't allocate region
7/21/10 7:35:58 PM [0x0-0x23023].com.apple.FinalCutPro[181] * set a breakpoint in mallocerrorbreak to debug
7/21/10 7:35:58 PM [0x0-0x23023].com.apple.FinalCutPro[181] Final Cut Pro(181,0xa01eb500) malloc: * mmap(size=16777216) failed (error code=12)
7/21/10 7:35:58 PM [0x0-0x23023].com.apple.FinalCutPro[181] * error: can't allocate region
7/21/10 7:35:58 PM [0x0-0x23023].com.apple.FinalCutPro[181] * set a breakpoint in mallocerrorbreak to debug
Thanks again,
-Mark

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