The file size change is an important clue. As I had changed Document Prefs>Save VP Cache in order to retain renders, I increased the file size, but unexpectedly dramatically. With all VPs rendered it was over 1GB!
The root problem is that though each VP is cropped to a close-up, the ENTIRE design layer is calculated THEN cropped, and it is quite a DL, less a model than an aggregate of all pieces/parts.
I would recommend more rigorous and liberal use of layers and classes to isolate, control, and organize visibilities. I played around turning classes off and got much better results, i.e. quicker renders and much less memory usage. I'm not sure of your requirements, but I would put different assemblies on different layers (including an invisible "Reference/Derelict" which I include in every file to dump development stuff), while using classes more as you have, to control types of parts.
IMHO, this is definitely the primary issue.
HTH.