Ran disk warrior and repaired permissions. Just finished copying entire project contents to new drive, but that is not the problem either. Did several tests with file size reduction (by deleting sequences) going down as far as 125 megs, so I dont’ think file size is it either. About to load FCP 7 to see if that will solve it, but I would have rather figured out the issue with current config. Of course no guarantee that the upgrade will solve it. Any thoughts appreciated.