Creating a cropped h.264 - 640x240 iPod compatable video from NTSC DV

Question: Does anyone know how to crop a 720x480 DV, 23.98fps video from Final Cut, to a 640x240, h.264 QuickTime file that is compatible with the iPod and TV?
I've been at this for two weeks, combing the forums for an answer to this problem, and have found nothing.
I have a weekly podcast that features 4 hosts. The standard 4:3 or 16:9 aspect ratios on my camera are not wide enough, so I have been masking the video in quicktime to 2.35:1 and using the "export for iPod" option under Export->QuickTime Conversion ending up with a masked 640x480. With the release of the TV I have been trying to create a 640x240 QuickTime video so it will fill the entire width of a TV as well as the iPod.
The show is shot with a DVX100A in 24PA, captured into FCP at 23.98 advanced pull-down, and edited all with the the 23.98 advanced pull-down easy setup.
Everything works fine until I try to crop the video and save it as a h.264, 640x240, iPod/TV compatible video. The big problem is finding the h.264 base profile and the AAC-LC (Low-Complexity setting), except the export MPEG-4 option in QuickTime Pro. Also, all the 3rd party apps I have tried do not crop the video and instead squish it vertically.
Does anyone know how to crop a 720x480 DV, 23.98fps video to 640x240 h.264 that is compatible with the iPod and TV?
Here is everything I have tried:
1. Export->Quicktime Conversion->QuickTime Movie
Problem: Does not work with iPod
2.Export->Quicktime Conversion->MPEG-4
Problem: Cropping does not work, video comes out squished
3.Export->Compressor
Problem: Any cropping of the video results in horrible video quality
4.Dropping sequence into a 640x240 sequence before export
Problem: Same as 3, poor video quality
I also tried all of the following 3rd party apps with a self contained QT file:
iSquint/Visual Hub
Problem: Cannot crop without squishing
ffmpegx
Crop and Auto Crop do not crop, squish video
MPEG Stream Clip
Cannot choose baseline h.264 or AAC-LC
All of these programs can export a 640x240 video, but iSquint/Visual Hub/ffmpegx all produced vertically squished video instead of cropping. MPEG streamClip was able to do everything correctly, just unable to select baseline and low-complexity profiles for h.264 and AAC respectively.
PowerMac Dual G5 2.3 Mac OS X (10.4.9) FCP 5.1 Studio

3.Export->Compressor
Problem: Any cropping of the video results in horrible video quality
Can you detail what exacts steps you're taking here? I export anamorphic 720x480 files (usually matted to 2.35:1) using the iPod setting all the time and, provided I specify the crop amounts, correct the frame size (ie. make it 640x272) and, most importantly, turn Frame Controls on, I get excellent quality.
Of course, having said that, you're trying to output a 640x240 file, so I'm guessing you're using a different setting in Compressor? Not the iPod preset?

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