cannot build variables_hash

[John Watson]

Upgraded from 1.2.9 to 1.4.1 and now started getting:

  [emerg] could not build the variables_hash, you should increase either
variables_hash_max_size: 512 or variables_hash_bucket_size: 64

Same configuration and even dropped (2) 3rd party modules.

nginx.conf and ./configure params:
https://gist.github.com/dctrwatson/6075317

adding this to http block fixes it:
  variables_hash_max_size 1024;

Any ideas? Or direction on debugging?

Thanks,

John
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