You may be developing cracks because you're putting the beads into a cool kiln instead of waiting for it to reach the garage temperature. Or, your kiln may not be keeping the temperature steady enough while you're working and cooling and heating in too large of a range.
Largest item? You do need to leave a bit of room around for proper heat sharing and to avoid cool spots. Most often you need to raise the kiln shelf off the floor - so I'd say no larger that a 9x9 or 10x10.
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Barbara
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