My project will only build an EXE in 8.5 but not 8.6, 2009, 2010, or 2011

Hi there.
I have come across bug in the LabVIEW programming enviroment.
I have a project that consists of about 600 VI's... ie very large.
The project compiles and runs perfectly fine and I can create an EXE in Windows 7 or Windows XP using LabVIEW 8.5 that works perfectly fine.
I can then take take this project and import it into 8.6, 2009 , 2010, or 2011 (after a very long time manually opening most of the vis and saving them - as the automatic method causes it to crash) - but once imported and updated the project runs fine in each of these newer versions of labVIEW.
The problem arises when I try to compile the project into an EXE...(using any labVIEW 8.6 or higher) 
the first error (or feature? who knows) is that instead of creating an EXE with the project name it instead creates a FOLDER witht the project name and proceeds to copy all the vis into this folder,... - i assume it must be part of the newer compile features and that after 5-10 mins it might delete those when it finally creates a EXE... but instead at the end it gives me a compile errror message saying it cannot save a Vi with a bad or missing block diagram.. (but the vi in question is fine when I open it, and it runs fine...no missing diagram etc)..
Normally in 8.5 I get the *.EXE and an *.alias file, and a *.ini and a folder called data with some dlls in it...
but in any later labview version the EXE fails to compile and I get random errors...
The 1502 error is the the most common..
but I get others too, haven't saved them all -
but error 6 has occured a few times...
Errors Codes
===============
Possible Reasons
================
An error occurred while saving the following file:
C:\[Calibre Backup]\02-OPC\2012-03-21- 8.6 US-58-OPC-F\Ecoustic Grader sub-vis\Ecoustic Grader grade board.vi
Invoke Node in AB_Source_VI.lvclass:Close_Reference.vi->AB_Build.lvclass:Copy_Files.vi->AB_Application.lvclass:Copy_Files.vi->AB_Build.lvclass:Build.vi->AB_EXE.lvclass:Build.vi->AB_Engine_Build.vi->AB_Build_Invoke.vi->AB_Build_Invoke.vi.ProxyCaller
<APPEND>
Method Name: <b>Save:Target Instrument</b>
Details
=======
Visit the Request Support page at ni.com/ask to learn more about resolving this problem. Use the following information as a reference:
Error 1502 occurred at AB_Source_VI.lvclass:Close_Reference.vi -> AB_Build.lvclass:Copy_Files.vi -> AB_Application.lvclass:Copy_Files.vi -> AB_Build.lvclass:Build.vi -> AB_EXE.lvclass:Build.vi -> AB_Engine_Build.vi -> AB_Build_Invoke.vi -> AB_Build_Invoke.vi.ProxyCaller
Possible reason(s):
LabVIEW:  Cannot save a bad VI without its block diagram.
============================================
Attachments:
details.png ‏22 KB

Hi everyone, thanks for the help, but its getting rediculous  for me....
I've done EVERYTHING that NI engineers on the phone and others have said..
in every permutation and combination as well...
I'm pretty sure the problem lies with labview not my code...
I've recoded the "problem" vi code from scratch... it runs fine in development mode..there are no broken arrows anywhere, and no missing block diagrams.
So as far as labview is concerned there shouldn't be a problem....
There must be a fundamental change from LabVIEW 8.5 to the other versions on the way the project gets built because this code works perfect in 8.5, but results in an error in later versions ONLY when Building - NOT WHEN RUNNING in DEVELOPMENT MODE....
Also there cannot possibly be a "conversion" error as some have suggested from earlier LabVIEW versions because I hand coded the "problem" vi from scratch in labview 2010 sp1 in case there was some sort of corruption with the vi the error code mentions.
There are no unused parts of the block diagram or code that does nothing as people have suggested..
(BTW the exact same issue happens in 8.6.1, 2009, and 2011 regardless. I just perfer to work in 2010 because its the last version of Labview that the same version of DAQmx will also work with 8.5)
When I go to make an exe of the project it again complains of the same error.
except this time it says the "grade board v2.vi" is the problem - the one that I rebuilt in LabVIEW 2010sp1
(BTW I do get this same error code 19 times out of 20)
Is there someone that knows exactly what this error refers to?
is there some way that the build process has changed from 8.5?
When I enable debug mode, this doesn't help as the final exe has a broken arrow
Attachments:
grade board v2 error.gif ‏16 KB

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