I have a rather large (several MLOC) application at hand that I\'d like to split up into more maintainable separate parts. Currently the product is comprised of about 40 Eclipse
Using OSGi could be a good fit for you. It would allow to create modules out of the application. You can also organize dependencies in a better way. If you define your interfaces between the different modules correctly, then you can use continuous integration as you only have to rebuild the module that you affected on check-in.
The mechanisms provided by OSGi will help you untangle the existing code. Because of the way the classloading works, it also helps you handle the patches in an easier way.
Some concepts of OSGi that seem to be a good match for you, as shown from wikipedia:
The framework is conceptually divided into the following areas: