[jeffrey durkin] “What’s the best-way to output this mixed footage
– Do I need to use compressor, quicktime conversion or make a self contained movie? “
Make a self contained movie of your DV timeline, open in compressor, and chose a DVD preset there.
[jeffrey durkin] “- Do I de-interlace?
– Do I do any sharpening? “
No need to de-interlace – 24p is already progressive. Shouldn’t need any sharpening.
[jeffrey durkin] “- And how do I make sure the image fit’s on a variety of flat panel TV’s? “
While in FCP, use the action safe and title safe lines in your viewer. (View>Show Title Safe).