Great to learn that yet more progress is taking place.Have you tried a job with a tool change yet?Once you can clear that hurdle a lot of possibilities open up,although I have used an initial program and called up a series of sub-routines using different tools and the original part location offset and it worked very well as long as the machine was homed before each run.

Drip feeding longer sequences gets you past the limitation of the modest amount of memory and it might be worth keeping an eye on ebay in case any memory modules turn up.I wouldn't touch the controller at this stage but having a bit more memory on the shelf sort of guarantees that it won't be needed.Likewise a high flow vacuum pump might turn up and is a very useful thing to have on hand.

Please keep the progress reports flowing.