I once faced the same problem, infopath doesn't seems to like property promotion on such a large scale. well try few times, it should succed, keep an eye on the performance of the server when publishing the form. Also you might want to go to the doc/form lib and confirm that there are no columns from the previous publish, i once had to clear lot of unused columns, which were left of unsuccessfull publishes.
The best suggestion would be to try and reduce the number of columns, as you are sure to keep facing such kind of problems.