Only 1K of EEPROM - I totally forgot that! 
I know I was thinking I had 2K to play with for some reason. But its 2K of SRAM. Rats.
I might have been testing with arraySize at 500 when it was working (just to have it complete faster).
Thanks, will scale it back some more tonight & see if goes back to working.
This is where the 2nd (and 3rd, and 4th) set of eyes comes in handy 