What about grid like this? It has 72 words and 38 blocks. You might have to be a bit lucky with your theme entries for it to work smoothly, but you also have 4 different ways to arrange the theme answers. If you want you can PM me your theme answers and I'll see if I can't find a grid and arrangement that will fill well.
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This is a good idea to try, but it was why I said you have to be lucky with your letters. 3 and 4 Down (and the symmetrical ones in the SE corner) are both 8-letter words that have to cross two themers. That's a tight constraint. Of course, if it happens to work out, then its a nifty grid.
The other tricky issue is 6-, 7-, 8-, and 9-Down are stacked 4s that end at the theme entry. That means the theme entry has to have end-of-word-friendly letters in just the right places. Not impossible, but constraining.