Aspect ratio 4:3 (because I made a sequence 1920×1440 and dropped my 1920×1080 into it. – NO
Choose 16 by 9, your edit is HD. You should make a 16X9 DVD
Don’t nest your comp, don’t make a custom size comp.
Edit HD native size to video.
Output a ref movie file.
drop that file into compressor
choose SD DVD 16X9 Letterbox
frame control set to best.
Dial in the data rate to match your program length.
Chris Tompkins
Video Atlanta LLC