Photomerge Workflow Help

Hi!
I was wondering if someone could help or tell me if I'm doing something wrong. I'm trying to create a panorama (images across and up/down) in PS CC using about 40-50 twenty MP images and I'm not sure I’m doing it the easiest and quickest way. My work flow is this:
Open images in ACR/Bridge > Adjust curves and other fine tuning > Apply adjustments across all images > Open RAW’s in PS > Photomerge > Wait 45 minutes….
It’s doing a fantastic job of merging the images, the blending is spot on and there are no errors in the image, which is surprising considering all the images were shot handheld! However, the resulting PSD is 2.6GB and doesn’t save unless I remove all the layers data etc. Should I be exporting the edited images from ACR into TIFF or JPG first and then merging them, instead of opening the CR2 files in PS directly from Bridge/ACR?
Also, I’m going through the above process twice on the same set of images. I’m adjusting the curves for the foreground in one set and merging, and then adjusting the curves for the sky in another duplicate set and merging, I then want to merge/paint in the sky from the second version of the panorama to create one pano. However, PS is stitching the exact same set of images together differently and distortion isn’t the same across the two panoramas. The images are exactly the same, only difference is the curves and exposure across the two sets, but PS is merging them differently and the distortion isn’t consistent. Any reason for this? I’d have thought that they would be stitched together the same, exact same files just different curves applied.
Cheers!

Photoshop is not the best program for stitching images but these days Photomerge does a decent job. When you capture image to be stiched you work-flow begins before taking the pictures.  For stitching to work well images need to be taken well. The involves setting your camera into manual mode and set all your cameras setting one way and take all the images without changing settings. Manual Focus, Manual White Balance, Manual Shutter speed all settings.  All adjacent images captured must have good overlap. If there are object near your  camber that will be captured the camera lens need to be rotated about its nodal point to avoid parallax errors. RAW will slow stitching.  So convert all RAW files to Jpeg or Tiff usine the same ACR settings. The stitch the RGB images.

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    http://www.e-workflow.org/
    http://web.mit.edu/sapr3/dev/newdevstand.html
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