Let me get this straight... You are attempting to make styles with over 128 bar long variations ? When could you ever use something like this? Doesn't playing a fill reset to the beginning of the loop? So to utilize this, you would have to play for WELL over an entire song (a lot of songs have 16 bar verses or thereabouts) and THEN some, without a single fill....

Why would you want to do this? I would have thought that 16 bars is the absolute limit to how long you are willing to go without a fill (unless you are doing hiphop!). Eight bars then a fill is pretty normal. Filling the style data with countless bars you will never get to seems pointless.

However, if you wish to get to the limit of a style's size AND still get as much bars in as possible, don't forget to strip out ALL aftertouch (plus any other continuous controllers) that may have got recorded. That can eat up the data pretty fast...
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An arranger is just a tool. What matters is what you build with it..!