48-Hr. Film Project Nightmare

Well, it's been quite a weekend for this editor. I was a participant in the 48-Hour Film Project - and everything was going okay until about 4pm yesterday, three and 1/2 hours before we were to deliver our finished film. At that point things went terribly, horribly wrong. I was trying to export an HD sequence to an SD-format Quicktime. I had done this before in tests and I knew it could be done, and knew how I wanted to do it. But when it came time, that's when the trouble started.
Every time I would try to export, I would get the most useless message I think anyone could get - "General Error". What??? And this happened EVERY time, no matter what format settings I tried to export with, no matter what I did. I closed out, trashed prefs, rebooted, ran disk utility to repair permissions - all with no success. We had a good entry, and the pressure was starting to rise. We could not get this $%^&^%$& sequence out of the box. Period.
We never did manage to get a file. With 1//2 hour left we went into a dark bathroom with an SD camera and pointed it at our Apple Cinema screen, running audio from laptop to camera and shot the screen. Desperation and ingenuity at it's best/worst. Shooting the screen ended up working okay, although there were exposure issues that we didn't have time to deal with. We DID manage to get our entry in, 4 minutes before the deadline - although nobody was happy with the outcome and what had happened.
The worst part about all of this is that when I returned home after going through all of this and turning in our entry, I started to look into what happened and immediately was able to export with no issues. I just wanted to cry uncontrollably at that point, and laugh hysterically at the same time. There are not words to express. After poking around some more the error did show up again using one of the sequence timelines I had created, but not anything like getting that "General Error" literally almost 100 times in the course of those two - three hours yesterday when I was trying anything/everything I know to get it to export just ONCE. I had the settings, I knew the drill - I had even practiced doing this before this weekend with the camera we used and did tests - all that went out the window when the export issue started.
All I could think about was how I was glad this wasn't a "paying client" but in reality, all the people who donated their time to our project were the client. At least we delivered something, but it was only a sad facsimile for the great looking and sounding short film we created. Everything I had done to try to avoid this nightmare was to no avail, and all I can figure is that in the process of editing, one timeline got corrupted and managed to keep any timelines from exporting, or something was corrupted on my video drive that reset powered off and then back on when I packed up my gear and went home. I don't believe I cut/reset power to the drive when all of the problems were happening, so maybe that had something to do with it.
Anyway, thought you might be interested in hearing about this - makes you appreciate not being me yesterday.

Contrary to the information above, your workflow was far from "unnecessarily risky...". Back in 2007 when the HVX200 was all the rage I helped more than one team in the 48-Hr Film competitions that Panasonic sponsored, they used a nearly identical workflow to yours without a hitch. There are some not-so-obvious benefits to shooting in HD and then making a downconversion to SD that many even today just don't understand.
The "general error" bug has haunted many a FCP editor - myself included - and unfortunately Apple has never been forthcoming in exactly all the things that could cause this error code. In fact, I had an Apple Pro-Care Tech support tech tell me that the reason it's called a "general error" is because the application itself is unable to determine the source of the problem. It happens.
As you've probably learned from this exercise you should be prepared to do some heavy-duty troubleshooting when things go awry; you've covered a few things in your list of attempts to fix the problem and here's a short list of other things you can check in the future:
- Connections to external drives, both in hardware (cables, power-supplies etc) and in software (making sure assets/preferences in FCP can still find those drives and are pointing to them).
- Get a copy of DiskWarrior and make it part of your regular maintenance routine.
- Speaking of maintenance, download Onyx (free app); use it's maintenance and cleaning routines regularly.
- Don't forget the obvious; I did see in your original post that you did all the initial troubleshooting (reboot, trash prefs etc) but don't forget things like basic hardware needs: Check internal power-supplies, make sure RAM is fully connected, listen for drive noises (like heads banging themselves silly).
Don't take this error bug as an issue with your workflow; HD to down-converted SD is not only safe but a preferential method for making superior-looking SD content whether for broadcast or DVD.

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