Hi David,
Well, it was a long, painful process, but the short of it follows…
There was too much transcoding going on, and at the wrong places. I will dig up the exact routine later tonight and post it, but one of the main tricks was exporting the HDV timeline before fonts were added as a QT movie with a DV50 codec, then creating a new timeline with this setting and adding fonts. Like I said, I will post a more complete description once I confirm with my edit partner.
In order to get this solution, we purchased the $799 Applecare Pro Video support package, and spent a while on the phone with someone from Apple in CA to work through the details. We have this service for a year and hopefully will find more use for it!
Thanks for taking the time to read and inquire…have you had similar issues in your travels?
Best,
Alex
Another Production Company