Help! my dvd looks really low res

I`m making a dvd of a feature shot on dv (24p, anamorphic) and exported from fcp5 in quicktime as 4:3 so that it would be letterboxed.
We are using dvdsp for the subtitles...since its letterboxed they go in the black space below the image.
In the encoding preferences we choose motion est. "best", and also "2 pass vbr"
But the image that comes out looks much lower res than it did in final cut...
The subtitles and title menus are the worst...we are using helvetica 24 (the universally recommended font for subtitles, right?) and the borders of the words are not smooth at all...
I have to believe we are doing something wrong...but where?

First, thanks for your help...we are running on the sundance deadline in 2 days...
I had heard about setting up the dvd so that it would adapt the dimensions to different players, but decided against it since its a subtitled film. Its just too hard to follow the story if the subtitles go superimposed above the image. And it looks like the only way to garantee that they sit below is to letterbox...I´m also pretty sure I set up my fcp timeline correctly (23.98 anamorphic, but stop me if I´m wrong there!).
So considering that what do you recommend for the workflow?
1. Export from final cut via compressor instead of just using via final cut´s "quicktime" movie option (but with what settings? I just did a quick try and it still looks low res...but I´m not sure on the settings)
2. Do the subtitles in DVD studio pro...
3. Then what? I dont see a way to encode in compressor within dvdsp... is encoding in dvdsp lower quality?
As for the other questions...I am just doing tests now on a single clip of around a minute duration so I have been using a bit rate calculator. The final film is 105 minutes.
I checked out p 230 of the manual and it seems like any menu with buttons that link to assets needs to get rendered...I´m confused isnt the point of menus to link to assets...how can I do this and not comprimise quality...and is the rendering something I need to do before burning, or does it happen automatically?
I havent been able to get access to a regular dvd player yet so I´ve just been testing on my computer...but compared to how the clips play in final cut the difference in resolution on the same computer is really significant.
I am using 90% white, also seems to be the industry standard for subtitles.
Thank you again for your help!

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