Hi Tom,
I’ve tried the “let Final Cut render it thing” and for me, it looks soft.
I let the Kona do the down convert (this way it is done in hardware instead of software) and send it to a monitor via component analoge if possible. You can then decide if you think I am right. If this looks good to you, you will need to figure out how to get this SD output from the Kona to DVD.
In my situation, I usa a Kona LHe which has component analoge out and send it either to a master tape for achieving or to a Pioneer PVR-LX1 for a hardware recording to DVD. If I need to have a custom DVD, I rip out those MPEG 2 files and AC3 files and author a disk around those files in DVD Studio Pro.
Chris