Please split it into 2 lines like casascius suggested. Are you creating compressed keys or not? Also, make sure you have tests that tests your code.
I had changed the font size slightly and got it to fit while still readable, most will use the QR code rather than trying to punch in 60 random characters anyway.
Anyway, yea I can split it to 2 lines, you want both encrypted and plain-text keys split on 2 lines?
I'm generating non-compressed keys. I guess I should add an option to choose.
Thanks for the reminder about tests!
In the mean time, you can find the code here to play with
https://github.com/Zeilap/bitaddress.org