So, it occurs to me some things I've written in this post are vague.
1. I've been using the full version of Breverb since November or so.
2. Last night when I opened Breverb, a message box said there was an upgrade available and 'click here to download'. I shut down Sonar and installed Breverb over top of the old DLL.
3. Immediately after doing this, my problems started.
4. I tried Preferences > VST Settings > Reset ALL VSTs > Scan VST Folders
5. Breverb does still work when auditioning the audio.
6. Perhaps the problem is with the specific Breverb Algorithm I had chosen.
a. I was set to Guitars > Deep Arp Algorithm. Dry was off and Wet was full (0).
b. after changing the algorithm to Guitars > Old Warm I managed a bounce to tracks and then immediately crashed.
c. after a restart I tried again and immediately crashed.
d. at one moment, I was auditioning with the global FX Bypass in the control bar enabled and I crashed. Breverb was technically enabled on the track, but the global bypass was on so ... ? does that exonerate Breverb? I had just finished my only successful bounce with Breverb Enabled in this project... did Breverb fail to clean up memory properly?
e. Curious, I restarted the project, disable Breverb, Enabled Perfect Space and Bounced successfully the exact same segment that had been failing only when Breverb was enabled.
f. Next, I opened an old 44.1 project and bounced successfully using Breverb's Guitars > Deep Arp Algorithm.
7. Beepster, I agree that the problem is probably associated with the enormous wave files I'm mixing. I do not have a problem at 24 bit 44.1.
8. Regardless of all else, everything works when I disable Breverb. And when I enable Breverb, Bounce to Tracks fails, every time in this one project 24 bit 192.