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It's tough, because these variations/customizations are legitimately what you do. My gut feeling, though, is that 80K (I'm seeing 90K with a site: search) indexed pages is just too much for your current link profile. It doesn't mean you'll get in trouble, but it could mean that your ranking power is spread far too thin. While it's not a decision I'd take lightly, I do think there's an advantage here to either: (1) Consolidating variations under one URL (2) Having multiple URLs, but possibly using rel=canonical (I think that's your best bet) to focus Google on one parent URL for each product