IMovie .mp4 export crapping out at about 20 gigs

We're producing 12 corporate videos from DV video files ranging in size from 6 gig to 30 gig.
When the smaller files are exported to .mp4 from iMovie 08, things go fine. But, when the larger files are exported, they fail at around 20 gig. Is there a file size limitation in iMovie, or is this more likely to be an issue of available RAM. Our 500 gig drive has 250 gigs of free space on it.
The job is being done on a MacBook.
Thanks in advance.

Thanks for the note.
I have a query to my shooter to check on the RAM thing. I suspect he is short on RAM.
Yes, the 30 gig is DV. The .mp4 files run about 2 gig for 6 gigs of DV. We intend to compress each 2 hour DV onto a single DVD.
I would do it on my own 2 gig MacBook, but my iMovie 08 won't recognize his project files for some reason. I would do it on my G5 dual, but it's loaded with iMovie 04, which doesn't load his completed timelines - it just loads the clips randomly in the clip pane. Why my 04 recognizes the files and 08 doesn't, I have no idea. It's a huge pain in the neck.
I'd buy iLife right now by download for my G5, but it only seems to be available for ground shipping (duh!).
I'm very frustrated with this.

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