IPod 5G Movie Length Limit?

Greetings,
I had earlier ripped The Lord of the Rings: The Return of the King (extended edition) onto my iPod 5G as two separate MP4 files (since it came on two DVDs).
However, I didn't like having one movie broken up as two files. So I converted the ripped ISOs to two MPEGs, and used MPEG Video Wizard to merge them together (I used this because I wanted the ending of the audio track of "Part1" to flow into the beginning of "Part2" - making a seamless transition).
The resulting 4h23m06s MPEG2 w/2-chan AC3 video is 9.15GB in size.
I used Videora iPod Converter to convert the movie into an H.264 320x144 768kbps widescreen video (cropped 60 pixels from the top and bottom of the original MPG - creating no black borders and maintaining the aspect ratio) with 128kbps 44KHz audio. Since it's only going to be viewed on the iPod, I wanted to keep the file size down and keep the good quality.
Now, I did a few tests. I first converted the original merged MPG file into a 3-minute sample, then loaded it up in iTunes. I went through without a problem. The video synched to the iPod with no problem.
Then I imported the full 4+ hour H.264 movie into iTunes. No problem there. But when I tried to sync it to the iPod, it got rejected ("iPod doesn't support...." yadda yadda).
So, not giving up, I made a 1h58m sample from the original merged MPG file, and converted that to an H.264 video (using the same Videora profile as before - it never changed). That converted file imported into iTunes and synched to the iPod with no problems.
All three videos were created with the same Videora profile, and all play in Quicktime and iTunes. Only the full-length movie will not sync to the iPod. I can only conclude that the iPod does not like videos after a certain length.
Also, I can't think that the file size is a problem. The 3-minute sample is 20MB, the 2-hour sample is 750MB, and the full-length movie is 1.7GB (not bad for a 4+ hour movie). I did a manual check, and the full movie's video bitrate is not quite 768kpbs.
Has anyone else seen this? Any advice? I have a beautifully edited and merged movie (that I spent some time to make perfect). And now the iPod won't love it appropriately. How rude of it to reject a movie that won 11 Oscars!
Cheers,
Keirmeister
HP ZD8000 Laptop Windows XP Pro

Then I imported the full 4+ hour H.264 movie into iTunes. No problem there. But when I tried to sync it to the iPod, it got rejected ("iPod doesn't support...."
This "long clip-short clip" problem is actually quite common and depends on both the content of your movie and the particular software used to encode it. Some applications use a "loose" encoding approach while others uses a "tight" one. Basically we are talking about how quickly the encoder responds to changes in the movie content and how well it modifies encoding to adjust for these changes. The longer a movie is, the more likely that sooner or later it will contain segments (dark scenes, rapid action on a compex background, etc.) the will cause your "peak transient" data rate to climb above the maximum allowed by the iPod. Clipping a segment to see if it will load on the iPod is only helpful if you can locate actual segmet causing the problem.
There are basically two strategies (three if you include changing encoders) you can apply to correct the situation. One is to switch from a multipass mode to a single pass and more or less keep the current data rate you are using. The single pass option in most allplications tends to "clip" these transient peaks meaning you do lose a bit of quality during those scenes. (I.e., you are trading a variable data rate for a more fixed one which has variable quality). The other strategy is to keep the multipass mode, but lower your target data rate. In this case, you are keeping a constant quality strategy but lowering the overall average data rate in the hope that this will provide enough "headroom" for your movie so it will not "peak" above the iPod's limit and will, thus, load/sync properly.
2.0GHZ G5/533MHz G4 DeskTop/400MHz G4 PB Mac OS X (10.4.3)

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