What codec are you editing in on the timeline?
You mention the need to smooth pixels. If you are having problems with text, graphics or photo edges, it may be that your QuickTime Video Settings in your sequence is set to DV. This will make your graphics look kind of crappy.
What version FCP are you using?
If you are using FCP4 and have QuickTime 6.5 installed, EXPORT a self contained QuickTime movie using the 8bit Uncompressed video SETTING.
Then open this movie in QuickTime and do am EXPORT from QuickTime to MPEG-2. Set your OPTIONS to ONE PASS. Target Bit Rate 6.5 Mbps and Motion Estimation Best.
If your video was good to begin with, this should get you good looking DVDs.
You’ll also have to convert the audio from AIFF to AC3 using APack. Here’s info on that:
https://www.kenstone.net/fcp_homepage/a_pack_warmouth.html
Good luck
David
Dual 2.5 G5 {OS 10.3.7}
4.5 GB RAM
NVIDIA GeForce 6800 Ultra DDL
DeckLink SP
ATTO ExpressPCI UL4S
Medea Video Raid RT320
Sony UVW-1800
Pansonic AG-DV2500
FCP Production SuiteHD 4.5
Media Cleaner Pro 6
Squeeze 4.2 (PC)
ViewSonic 19″ LCD
Optiquest 21″ CRT
Bella EZ Keyboard