See this for details:
harfbuzz/boring-expansion-spec#159
I suggest we implement that already. That is, if the VariationStore struct's length field is 65,535, then allow the embedded ItemVariationStore to reach out to the rest of the font file.
@justvanrossum has been building a font that hit that limit.
We are going to also implement this change in FontTools and OTS. HarfBuzz already renders such fonts fine, and I will test FreeType and report.
OTS report: harfbuzz/boring-expansion-spec#159