[Jason Groh] “Frame Size 1140 X 1080”
Are you sure it isn’t 1440 x 1080?
Also are you using export quicktime movie, export to Compressor, export quicktime conversion?
If so what are your settings and are you looking at the file in quicktime or imported back into FCP. What does quicktime tell you the codec of the exported file is. Do you have the option set to view high quality in quicktime?