HDV and Animations brought in to HDV timeline

Yes, it's a funky format, yes, I will work with my client to convert to ProRes or DVCPROHD codecs next time (he says as his mantra).
I have an HDV 1080i60 show I'm wrapping up. We are going out to SD DVD for the first consumer run of this show. I'm bringing in some animations from After Effects (and Motion for that matter) which look great in the the HDVTimeline and in the quicktime output...but...
Current workflow is HDVTimeline out to HDV1080i60 Quicktime --> Compressor SD DVD settings --> DVD Studio Pro --> Burn
Footage is looking good (enough) but my animations begin to chunk up (well at least on LCD monitors -- flatscreens, consumer flats, etc.) on NTSC Tube TVs they are beautiful.
I'm sure this is an interlaced/SD/progressive thing so those "in the know" I'd appreciate some thoughts.
Please no "Pro Res or DVCPROHD" comments, I'm well aware of where these shows I'm doing for this particular client need to head.
cheers all.
dj

Yo David!
I don't know if I would consider myself "in the know" however
An LCD display is going to give you alot better resolution than your old NTSC tube TV, so you're going to see the compression and imperfections that you don't see on your old crt.
That being said... I have had issues from time to time encoding for DVD with footage from my FX1, so much so that if I know I'm only ever going to DVD with something shot on HDV I downconvert during capture and edit in DV Anamorphic.
Some things I would try at this stage of the game...
First off - I would go through the standard trouble shooting formalities?
I would try to follow down the line to see at what point your graphics start to "chunk up"
Is it something with the original "downrezed" graphic? is it something with the flat panel? is it something with your mpeg compression, or does it happen when it gets burned to the disc?
I would play with the bitrate and compression. I've had better luck on several occasions with the fast encode rather than the best encode, as well as varying bitrates.
You also might try importing a QT REF MOVIE into DVDSP and let DVDSP handle the compression.
What happens if you do a quick test and recreate one of the troubled graphics in 720x480?
If that doesn't work you might look at encoding with bitvice or some other 3rd party compressor.
Good Luck,
JR

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