I need help with export settings

Hi everyone,
I need help outputting an HD file for presenting a video to a client. I have tried exporting to HD .mov (H.264 codec) and PE keeps crashing (error compiling movie). From what I’ve read here, it’s due to the gargantuan file QT creates and HD space (even though I think I have enough HD available).
So, I need a recommendation from you on what kind of file to output which will allow me to present the movie to the client in HD. This file is solely for the presentation, I have already published for web (FLV) and YouTube (direct share from PE) and they both worked fine.
Here are my project specs:
Timeline:           4:26
Format:               1920 X 1080 HD
Timebase:          29.97 frames per second
OS:                        Windows XP SP3
Processor:          Intel Core 2 Duo @ 2.66GHz
RAM:                    4GB
Project Drive:   250GB disk with 152GB free space internal dedicated project drive (separate from OS)
Thanks in advance for your help,
Jose

Hi Steve, Neale,
I wanted to follow-up on this post. I came into the office today to run a few tests so I can make sure that I have the correct settings on my camera and PE project for the next time around. Here are few observations I was wondering if you can comment on:
My Sony camera cannot shoot HDV. The only format it supports is AVCHD, so I'm stuck converting.
I tried to convert the footage I have to HDV with the software I have (AVS Video Converter and Koyote Soft HD Converter) and neither of the two have an "HDV" conversion setting. I see AVI, MPEG, MOV and many different settings in each (AVI: Hd Video 1080p: H.264AVC, 29.97fps, 4200kbps, Audio MP3, 256 kbps or MPEG: HD Video 1080p - MPEG2, 15000 kbps, 1920X1080, 29.97fps, etc). What should I be looking for?
I searched for "best file format" in the forum and found various postings from both of you referring to converting to DV-AVI within PE; especially if you have AVCHD footage (which I have). So, I followed directions and converted a file for testing. Then, I created a new project using HDV 1080i 30 settings and imported the converted file. I still get a red line on the timeline. Any thoughts on what I'm doing wrong?
I also converted the MOV files (shot in HDV 60i with the pro camera) to DV-AVI. I also get a red line on the timeline...
The DV-AVI converted footage (both cases) doesn't appear to be HD. It looks jagged on the preview window. Is it HD?
The DV-AVI converted footage is almost double the file size as the MTS (AVCHAD) file (138mb vs. 60mb). Isn't that going to make PE run slower?
Thanks in advance for your help. I just wanna make sure I do my homework now so I set everything up correctly on the next project.
Jose
P.S. I almost forgot! Here's the link to the live video on YouTube: http://www.youtube.com/watch?v=fEkqPmefJV0
Message was edited by: josejb70 - Added YouTube link

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