Hi Cliff,
Sorry, it looks like the topic for your post was a bit long and the forum truncated it. My guess is that this contained vital information about the failure you're experiencing. Unless you can give me any more information, I'm assuming this is a memory consumption problem.
NCrunch v2.11 introduced a major feature called 'Engine separation', in which the NCrunch engine is hosted outside of devenv.exe - see
here for more information about this.
I highly recommend upgrading to the latest version. The major motive behind the engine separation was to fix memory consumption issues inside devenv.exe. Give it a try and let me know how it goes.