Blu-ray authoring in Encore - importing from FCP

I do all my post in FCP and I am shooting HDV 1080i and then want to burn Blu-ray using Encore. I tried creating a quicktime reference file and then importing it to Encore - the SD DVDs look okay (with jagged edges at times - interlaced video problems I guess) and play back fine. However, the Blu-ray wont play back (it burns fine) on the Sony BDP-S300. Any suggestions as to what might be going wrong?...My video length was 60 mins and Encoe showed the size as 8GB (which seemed a bit low for 60 mins of BD). Let me know if you have any suggestions on troubleshooting. I used the automatic settings for transcoding for now (I will customize the transcode settings once I know I get the BD to work)

Does your Sony player have the latest firmware updates?
Try encoding the video as Mpeg-2 in Compressor for a BluRay file, then import into Encore. It should say "Don't Transcode" under the BluRay transcode settings if you got it right. Letting Encore do all the encoding is a bad idea for both of those options. Even for DVD I would use compressor, Sorenson, BitVice, or similar encoding software...but since Compressor is free with FCP....
Burn the disc, or burn a bluray ISO then use another program to burn the ISO to your bluray disc.
I would suggest investing in 1 or 2 BD-REs to make this part less expensive.

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