IPod maximum video time limit?!

i've been converting some DVD's to ipod format for my 5G ipod.
(using Handbrake to make a mpeg-4 file that i then use Quicktime Pro 7.0.3 to convert to iPod format)
I have had no troubles and the video looks great but i have noticed that iTunes won't allow me to put a few movies onto my ipod.
for example Cinderella which is 75 minutes works great as does everything i've done that is shorter than that (45 minute tv shows 7 minute cartoon shorts etc) but when i try to put Raiders of the Lost Ark or Star Wars (115 minutes and 125 minutes respectively) they get refused when trying to load to the ipod.
all the movies are made with QT7 Pro and fall well within the specified iPod video specs.
this morning i exported a 20 minute chunk of Raiders and it worked fine.
has anyone had any luck with movies longer than 75 minutes?
is there a maximum movie length the ipod can handle?!
-Don

Are you suggesting that Quicktime 7 is failing to keep the bitrate within specs? the resulting movies say their bit rate is in the range of 625-660 kbps.
While I also find this "double conversion" process of yours a bit unusual, if it works for you, what can I say? Don't believe QT Pro is creating files beyound the iPod limitations (as confirmed by your data rate readings), I am curious about a few other matters. For instance, HandBrake has a habit of resetting frame rate to 24fps if not manually overridden. Wondered, therefore. if you are overriding them for your intermediate MPEG4 file. And, if the intermediate MPEG4 file is at 24fps, what is the final frame rate in the H.264 file created by QT Pro? (Have never tested to see if QT Pro maintains the sorce frame rate or attempts to reset it to the more normal 29.97fps.) Also wondering what MPEG4 data rate you are using for your intermediate file. Unless you are using a combined audio/video data rate on the order of 2000-2200kbps, it seems to me you may be creating an inferior intermediate file and then possibly forcing QT Pro to work harder in an effort to correct matters. What about resolution? Are you dropping it immediatelly to gain processing speed in later file processing or are you "stepping" down the resolution change gradually? Normal workflow requires (or at least implies) that each preceeding file should maintain a level of quality (by virtue of frame rate, resolution, data ratre, etc.) slightly greater than that of each succeeding file.
As I said, have not run any tests to see what sort of impact these various aspects may have on your final target file. It may be interesting to run some tests when I have the time just to get some idea as to what may be going on here. Rule of thumb in most cases is to apply the old "KISS" approach -- "Keep It Simple, Stupid." By this I mean to say that it is sometimes better to keep things as simple as possible so as not to introduce unanticipated problems. Question: Do the files which are created directly (but too dark for your taste) sync to/play properly on the iPod?

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