[Angelina Leger] “1 – Why is quality poor in regular QuickTime export? File size is huge but quality is horrible. It looks better when I use Conversion as mp4. “ DV is roughly 13GB/hr.
How are you looking at this to judge quality. DV is a codec for TV, to judge that you need a TV connected to you system. Take this DV movie into QT Pro and try to encode it to H264. If you don’t have QT Pro you need to get it, it’s only $29.
[Angelina Leger] “2 – Could the .avi files be the source for crashing while exporting using QT Conversion to .mp4?”
Try exporting a version without these files. If it exports okay your answer is yes.
You have to realize that once you start using formats that are not recommended you are “entering at your own risk.” FCE is a great product for what it does but it only deals with a couple of codec, you need to stay in these codecs. Transcode AVI clips (in QT Pro) to .mov DV and things will be much smoother. Get things right at the beginning of the project, in the long run it is almost always faster.