It looks like PD is choking on the amount of data (but that seems unlikely)
whats unlikely aobut that? its not hard to make software choke, especially when involving feedback loops..
Again I don't want to use a second PD instance since the data I want to work with the is creation of the patch that works with the data!
in software feedback overload situations it does help to have a second instance, with the first one niced to a suitable level so that the second one can actally record to a file and transcieve to the d/A properly. but usually the first one goes nuts and crashes jackd and causes unpredictable CPU spikes so you really want a second computer..or a tape deck...