In-house, high-definition video making

Hi all,
We are considering to make a switch to high defintion video making. We are a small manufacturing company and we've had quite a number of new products introduced recently. We then need new videos of our products, and are thus considering to upgrade to HD (mainly for better trade show impact, first).
Sor far, all-in-all, with the camcorder, eMac, DVD duplicator, VHS (for VHS making), and a bit of iMovie hacking, we've been able to have quite professionnal-looking videos made in-house, for probably under 6k$ of investment. I'd be glad to go HD without investing 50k$...
I'm a big fan of Panasonic 3CCD camcorder. We've been well served with the one we have (PVGS120, with a dash somewhere). Now that the Panasonic AVCHD 3CCD are out, I think it might be time to make a move.
The plan is this:
- shoot with Panasonic AVCHD 3CCD camcorder plugged via HDMI-out to HDMI-in of BlackMagic Design's Intensity card (PCI);
- capture this shooting on-site, in uncompressed HD onto RAID (I know, that won't be lightweight, but, hey, I won't be doing this 365d/y);
- edit and deploy with Final Cut Studio
However, before I go any further, I'm seeking answers on the following...
1. In Final Cut Pro, is it possible to capture video from the PCI card but capture audio from Toslink-in (on Mac Pro), with no sync problem? I'm asking because the Intensity card will downgrade audio to 2-channels (from 5.1-channels the camcorder outputs).
2. Does anybody know of another way to extract audio from a HDMI cable to a Toslink cable than the Gefen's products (which makes, besides other, a HDMI-in to DVI-out and Toslink-out)? Technically speaking, could it be possible to simply have a HDMI-Toslink adapter cable? I'm wonder if there are very deep differences in the way the audio signal is encoded in both cable...
3. Can Final Cut Pro capture uncompressed HD signal and save it under a lossless-compressed format on the fly? Or do I have to save it uncompressed first, go back to the office, and then run compression...
4. Speaking of lossless compression, I've read in diagonal about MSU, and Lagarith, YULS and others... Which Final-Cut-Pro-supported codecs do you recommend?
5. Finally, and I know that ain't FCP-related, do you know if it's possible on Mac OS X to have one single computer displaying two or more full-screen HD video, each on its own display?
I'll be looking forward for your comments on this, as it will help me budget the whole idea and come back to earth if that is too much $$$
Thanks in advance,

Thanks very much.
Let me say I very much look forward to reading your book on PE7. I self taught on PE4 and thats definately NOT the way to learn anything.

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