Media Encoder corrupted output

Media Encoder reports successful encode.
The logs report no errors.
In fact the only output is 2 intermediate work files, video only and audio only, the correct audio-visual output file is not there.
The attached JPEG screen print shows the 2 file types.
Basically, there is a short-circuit in the encode process.
This just started happening out of the blue. It now seems to happen for every encode even for things that encoded OK before.
I am running with just 4 second encodes that is 1st 4 seconds of sequence, until I can figure out and correct the cause.

FIRST, the workflow. For the reasons why Encoder outputs become inputs.
You do not do video projects all as one physical project.
You break them into stages.
I have three stages.
All documentaries have a "stage", so the narrator is not floating in empty space.
My stage is in the countryside.
So first I filmed in the countryside mostly during moonlit darkness.
You cannot film landscape and moon at the same time because exposure range is too great and perspective is wrong that is if you use the right zoom for landscape the moon will be a tiny little burnt out white dot.
So I did multiple shots then composited them together, the result is moonrise, foggy country river night landscape, with then proper sized and exposed moon traveling across the scene then leaving. Stuff like that.
All that is one project, it all goes together through Media Encoder, out comes my stage.
You cannot sit in the countryside narrating a documentary at night, this is impossible, you need an autocue etc and several takes. Adobe could not handle the chroma key cloth I was using so I had to set up a tent indoors instead and use a 16-point cut-out to make the surroundings transparent. So my video of me narrating the documentary is several sections of narration stitched together (it is 5hrs 14mins) in a tent laid over the countryside stage and minimised to bottom left corner of screen, because the star is not me but these documents that I am going to show you, so I give you a story and interpretation but the documents show this is for real. So this is the second project, me performing narration composited over this stage. That is a second project and encoding.
The output from Encoder for this second project took 2 weeks to produce (that is Encoder ran 24 7 for 2 weeks to produce the output) that output was missing audio so it became the input to a third project where the audio was re-attached to the video. This third project became the input to the 4th and final project which is where documents are displayed.
You cannot display documents in SDTV, these need HDTV at 1920x1080 and that is how the whole project was conceived. The camera I used produced 1440x1080 but this was converted via Encoder to 1920x1080. The documents are scanned into computer or otherwise are computerised data, they were displayed on Windows Vista using 1920x1080 resolution, then JPEGs were produced of the windows containing the documents (this is because Adobe Pr Pro is not 'aware' of computer data not even from other Adobe apps like Acrobat). So I produced the JPEGs and started getting them to work with prior Encoder output, although this eventually worked (see thread http://forums.adobe.com/thread/690645?tstart=0) it was realised that the prior Encoder output is in a version of H.264 that is not compatible specifically with Blu-ray, so I have to re-encode. Then I have to check the JPEGs can be compatible with the re-encoded Blu-ray type output. This re-encoding isnot going smoothly.
SECONDLY results of the Encoder run are that I got the three files video in .m4v and audio in .ac3 and a blu-ray related file .XMPSES.
Nothing outside Pr Pro will play the audio or the video. I pulled them into a Pr Pro sequence and Pr Pro plays them. For the video there are now signs of degradation in the form of horizontal striping which I will guess is caused by multiple encodes especially this last transform from H.264 of a very high quality down to this lesser quality. I can later re-rerun my earlier project that re-attached audio and produce outputs directly in the desired Blu-ray compatible H.264 and see if that fixes the problem, but next I want to check a third party multiplexer and see if it produces a file that will fit on Blu-ray.
The outputs from the latest run converting to Blu-ray H.264 without multiplexing produced files which in total are about 39 gigabytes, we know already that if Encoder performs the multiplexing it will blow the Blu-ray limit of 50Gb. So I want to try a thrid party multiplexor on this output to see if others are more efficient.

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