I hear what you're saying about legacy code...
Something you might want to be looking at for the future is migrating to a structure where the data is stored in a 1D array, where each element is a cluster contain the data that's now in a single row. This would be the most straight-forward change, but could make getting at the data tricky, depending on how you need to be able to search it.
Alternately, you could have a cluster containing arrays of each of the row values.In this structure element 0 of all the arrays is the first "row", element 1 of the arrays is the second "row" and so on. This structure at first blush looks more complicated, but it's really not, plus it would allow you to use any value (or combination of
values) to search for a specific row without a lot of parsing.
If the data that is in the example VIs you posted is typical, either of these changes would be advantagous because it looks like there is a lot of reptative data that might be able to be encoded in an enum. Plus storing numbers as numbers often reduces the memory required and produces a predictable memory footprint (an I32 will always take-up 4 bytes per value regardless of how large of small the number is). My sense is that the variability of the string size is what's killing you.
One thing that would make this sort of dramatic change somewhat easier is that because you are changing the basic datatype of the interface, you aren't going to have to worry about finding all the places the change will effect--the wires will be broken.
If you ever decide to take this on, give a hollar.
Mike...