Final Cut Pro + HDV export = Stressful Day

Equipments:
* MacBook Pro 2.16 GHz, 2GB Ram, 120GB Hard Drive, OSX, Final Cut Pro 5.1.4, Sorenson Squeeze 4.5, DVDSP 4, Compressor 2 and many other softwares.
* Sony HVR-V1U, connected to through FW800.
* Project: 80 Hours of Footage on 2 USB External Hard Drives. 500 GB MyBook and 750GB SeaGate. 30 Minutes Final Product 1080i60. Captured and edited on Native HDV instead of AIC. 1440x1080 frame size.
* Problem: Export Project. It was succesful before on 3 minute trailer. However, the same method doesn't work on 30 minute project.

Methods:
DV50 Method > To keep 16:9 ratio, higher DV quality:
1> Make a DV50 Timeline on FCP.
2> Drag HDV timeline to DV 50 (need rendered) but I didn't. Don't need to. It's just for export.
3> File>Export>Quicktime Movies - Make Movie Self Content
4> Re-Compress on Sorenson Squeeze.

Result: 1.5 Hours. Color are off. Video are choppy and keep skipping. No good.

HDV Method > Export as a current setting:
1> On HDV Timeline
2> File>Export>Quicktime Movies - Current Setting > Make Move Self Content

Result: 2 Hours. Color are right. Video keep dropping and skipping. No good.

Uncompressed 8/10 bit Method > Best way to export for DVD, so the title won't pixelated:
1> On HDV Timeline
2> File>Export>Quicktime Movies - Uncompressed 8 bit NTSC> Make Move Self Content

Result: Test Field 2 Minute. Color are right. Video works for the Test Field of 3 minutes. However, it's 3:4 ratio instead of 16:9 ratio.

Modified Uncompressed 8 Bit Method > I have control of what I want:
1> On HDV Timeline
2> File>Export>Quicktime Movies - Custom Setting
3> Frame size: 960 x 540 (Whatever I want, it's custom and it's 16:9)
4> Pixel Aspect Ratio: NTSC - CCIR 601/DV (720x480)
5> UN-check Anamorphic (I already set frame size to 16:9)
6> Field Dominance: None
7> Editing Timebaes: 29.97 (I know it's 60i, but 29.97 seems to work best for me)
8> Timecode Rate: 30 Non-Drop Frame (It seems to work best for me, instead Same As Editing Timebase)
9> Compressor: Uncompressed 8 Bit NTSC - at 80% Quality. You don't need the 100%. I don't think. It's going to be on SD-DVD or on the web.
10> Make Movie Self Contained and Save.

Result: 6 Hours. I can't wait. The Director were leaving in 3 Hours. Will update on next project.

HDV Tape Method> It's an old method when DV tape just came out. Print it back to the tape and capture it in DV mode.
1> On HDV Timeline
2> Render All (⌘ + R)
3> Print to Tape (FCP 5.1.4 Can't Edit to Tape. I can't even playback HDV Timeline on HDV mode camera)
4> 30 Color Bar - 10 Black Front/End - Automatically Start Recording
4.5> Audio/Video Setting
4.6> A/V Devices Tab
4.7> On Different Output for Edit to Tape/Print to Video - check it
4.8> Uncheck on "Mirror on desktop" (I read this somewhere, and it helps a lot. If not, the video is going to stop after your color bar, and you wasted 1 hour of waiting till the video is ready, and have to start all over again) and Save.
5> Click OK
-
6> After 1 Hour preparing for Video and 22 Minutes to Print to Video, Change the camera mode to DV convert.
7> Capture on DV mode anamorphic.
8> Compress it for DVD and web.

Result: During the Print to Video, there were 3 spots it was skipped and Timecode Break. I have to find a better way to Print to Video, cause this is the best method so far. Good color. Not choppy. Take the same amount then export it straight from FCP or Compressor.

Camera Settings:
Before Export HDV on Sony V1U:
1> In/Out Rec
2> VCR HDV/DV mode make it HDV not AUTO
3> i.Link Conv is OFF

I did differently, and it just doesn't work.

Before Capturing back to FCP on DV moe:
1> In/OUt Rec
2> VCR HDV/DV mode make DV
3> i.Link Conv is ON
4> Down Convert is Letter Box
5> DV Rec Mode is DV SP, it's because I used regular mini-DV tape.

I just did this cause this is the setup I want.

I would like to hear any other way. Better or Faster.