Cannot export HD from Premiere Pro CS5.5 XDCAM HD 420 projects

Most of the sources material is XDCAM HD 420 35 MPS. There are a few MOV clips in there as backgrounds and some, not many Boris Red 5 transitions. No matter what I try, I cannot export to Bluray. I cannot make a bluray via dynamic link. I was able to export NTSC AVI files of each of the five modules, rebooting the computer after each of the 5 exports and not rendering the effects in the timeline. Used the AVIs to make the FLV and WMV clips. However, I still need to make a Bluray in order to get paid.
Is there such a thing as a corrupt project? This project started its life as CS5 but it started endlessly indexing renders (I mentioned that before a few months ago but with CS5.5) so I brought it into CS5.5. If I render the effects in the work areas it starts the indexing renders circle dance so I don't bother, jsut exported to AVI.
I've removed ALL unused media and ensured that every one of the 5,000 files is in the single directory on an AVID SCSI Ultra320 RAID.
I cannot export via Project Manager, it just quits.
Any ideas are welcomed.
I am running this on a Supermicro MOB with two quad XEONs, 32 gig RAM, nVidia QuadroFX 3800 and two channel Ultra320 SCSI. Win7 64 bit Ultimate. I tried swapping the Quadro for a GTX 570 but nothing improved.
thanks,
Peter Burn

"Why not?"
If I knew that I would be very happy indeed. I am reinstalling CS5 to see if it will export this project. I bought the newest version of Diskeeper and defragged all the SCSI and SATA drives, still no joy. Exports get to about 25% then Adobe freezes up completely. I may have to put the AJA Kona back in then try exporting via HDSI to a rented deck.

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Height: 720
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function(){return A.apply(null,[this].concat($A(arguments)))}
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Audio #1
ID                               : 2
Format                           : PCM
Codec ID                         : lpcm
Duration                         : 2s 760ms
Bit rate mode                    : Constant
Bit rate                         : 768 Kbps
Channel(s)                       : 1 channel
Sampling rate                    : 48.0 KHz
Bit depth                        : 16 bits
Delay relative to video          : 4h 14mn
Stream size                      : 259 KiB (2%)
Audio #2
ID                               : 3
Format                           : PCM
Codec ID                         : lpcm
Duration                         : 2s 760ms
Bit rate mode                    : Constant
Bit rate                         : 768 Kbps
Channel(s)                       : 1 channel
Sampling rate                    : 48.0 KHz
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Audio
ID                               : 2
Format                           : PCM
Format settings, Endianness      : Little
Format settings, Sign            : Signed
Codec ID                         : sowt
Duration                         : 9mn 26s
Bit rate mode                    : Constant
Bit rate                         : 1 536 Kbps
Channel(s)                       : 2 channels
Sampling rate                    : 48.0 KHz
Bit depth                        : 16 bits
Stream size                      : 104 MiB (4%)
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