Since upgrading to 2.1.1 we have not had many export problems, but when we were using 6.1 things were different. I never had the version you are using, it could be something that’s fixed in later versions. Here’s our experience and solutions to export problems. We stopped using the “send to:” function and started doing and export QT movies (not reference), then using Procoder instead of Sorenson to compress. Works perfectly nearly every time. Then we go to Encore for DVD authoring. If you do not have Procoder, try the QT Movie to Sorenson directly and that usually works, although the compression isn’t as good.
Duane