Thanks for the help.

I left something out of the story that apparently is a big deal. The vox track is a comp track that has 4 layers and edited with mutes, etc. 

When I take this comp track and bounce to another track (no sends/no fx - RAW) I get the same large peaks and distortion. I noticed the faders on the slow bounce and they were redlining. The track is recorded around -12db.

No Melodyne, nothing, just a comp track. 

I take this same track and bounce to clips and it looks normal. I listen as well. I then bounce the track to another track and again it is normal. I add Melodyne and do a few edits to the now non-comp's track and bounce to tracks - all is normal...  I should add that I also froze the comp'd track and bounced and it was also normal.

In the end I'm left with thinking I can't bounce a comp'd track to another track - I have to first bounce it to clips or freeze it??? That can't be right. 

BTW - fast or slow bounce didn't seem to affect the clip once I froze or bounced the comp'd track (in place) and then used Melodyne - then bounced to another track. 

Must not be a Melodyne issue after all...

Anyone care to comment, I would appreciate it. At least now I have a trusty way to this.