Yeah, I hitted it with pChat at the begenning of Chat restoration (I was dumping whole chat in saved vars).
You should look at mastermerchant way of managing this. I'm also working on a big project which will meet this limit, so i'll try to find a workaround.
Consider that if lua file is > 20MB , it has huge chance to be corrupted. After 32MB , it's 100% corrupted.
Maybe array indexes which can fail after some limit .. 4k or something.
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