Hi Tom,
The truth is that there are more than a few things that don’t work right when you choose “Other:” while exporting. It’s on our list of “things that would be nice to fix” (if we can), but it usually gets pushed back for new features or show-stopping bugs. Because of this, exporting a Self-Contained or By-Reference movie and then running THAT through QuickTime Pro is the most reliable way (for now) IF you want letterboxing in your exported file.
Having said that… if I understand what you’re doing correctly, I’m not so sure you really DO want the letterbox in your exported file.
If you’re working on an HD Program, which is 16×9, and you want to send a small, compressed version of it for the client to see on their computer, why not export a movie in a 16×9 aspect ratio so it just opens up in QuickTime player at the correct aspect ratio?
This has a few of advantages:
– You don’t need to involve another application.
– You only need to export once.
– You aren’t adding to the file size with black bars top and bottom.
– It looks cool when it opens up 16×9.
Using your mention of 352×288 as a guide, I just tried the following and thought it looked pretty good:
– Other: QuickTime Movie
– Click “Options”
– Set “Size…” to 480 x 270 (leave everything else alone)
– I set my compressor to H.264 and set the Key Frames to Every 300 frames (10 times the frame rate)