Gordon,

>1. The config.fpw has the temp directories in it as well as MVCOUNT=6000 (Foxfire requires this to be bumped up.)

It wouldn't be that the previous EXE required, say, MVCOUNT=4000 ?
Just note that when some limit is exceeded here, all will be slower. Has to do with the first memory allocation Fox does at startup (something like that).

Further, from your descriptions I derive that all is rather stressed already. I mean, 15 seconds for a form to load ... Now, just think of it all needing just a small step of additional resources, and the whole starts paging-out its own needed memory. So carefully think of what your changes in the new EXE were ...