A lot of different info going on here. If you are going to SD tape you are going interlace. You can set the pull down scheme in the Kona Control Panel to be 2:3:3:2 which should allow for a cleaner pull down removal when you capture the footage from the SD tape to get it back to 23.98p.
[Ted Joyce] “can I anamophically squeeze it to 4:3” with compressor there is never a reason to do this, it should be 16:9 anamorphic (1.2 aspect ratio).
[Ted Joyce] ” For reviewing copies it is hard to beat the speed of realtime playback into a standalone DVD burner.”
Why not go from the HD timeline to the DVD Recorder to burn your DVDs?
Personally I would make HDCAM tapes which can be 23.98.
[Ted Joyce] ” I transferred the 15 year old 4:3 16mm film anamorphically filling the entire 16X9 HD frame.”
In doing this you have to be cropping the top and bottom of the image off. This is not a right or wrong thing but a is that what you wanted thing. When you down convert the HD to SD with a center crop you loss some off the right and left, so you are left with a center punch of the image that was on the film. You have lose some off the top, bottom, left and right.