Letterboxing HD sequence for DVD to play on standard TVs?

Question

I have edited a sequence in Final Cut Express 4.0.1 that is HD 1440x1080, Apple Intermediate Codec, 25 fps.
I would like to create a letterboxed version to place on a DVD that will play on standard size TVs -- and keep the quality of the original video.
Here's what I've tried:
1. First, I used "Easy Setup" to create a separate NTSC sequence. I then dragged my original HD sequence icon into the canvas of the NTSC sequence and dropped into the overwrite box. However, it says, "Your sequence should be set to the format of the clips you are editing. Change sequence settings to match the clip settings?" If I say yes, the new sequence becomes like the original sequence, which defeats the point. If I say no, it gives me the error message, "Operation not allowed. You cannot nest sequences with different editing timebases."
2. I exported my original HD sequence as a QuickTime movie. I brought that .mov icon into the browser, then dragged it into the canvas of the NTSC sequence and dropped into the overwrite box. This successfully creates a letterbox, but the quality of the video suffers greatly. I would be embarrassed to show this version.
3. I exported my original HD sequence using QuickTime conversion. I tried many different settings, sizes, etc. I often checked the "Preserve aspect ratio using letterbox" option. However, no matter what I did, the video was distorted every time, not letterboxed but stretched vertically.
4. I tried creating a DVD with the .mov of my original HD sequence. In iDVD, I burned two copies, one using the 4:3 setting and one using the 16:9 setting. Both created a DVD that plays fine on my computer, but is too wide to play correctly on my TV. The edges of the picture go off the right and left sides of the TV screen.
I need to be able to put this sequence on a DVD that will play on TVs. Does anyone have ideas for how to solve this?
Thanks for your help!

Answer 1

Hi Tom,
I really appreciate your help!
Yes, it seems the original material is widescreen.
I am using QuickTime 7.5.5. In the QuickTime Movie Inspector, the values are:
Format: DV, 720 x 480 (853 x 480)
Normal size: 853 x 480 pixels
Current size: 853 x 480 pixels (Actual)
However, in Final Cut Express the same clip in Item Properties has a value of:
Frame size: 720x480
But I can see just by looking at the video that it is not standard size SD. So I tried:
1. Copying the edited clips from the timeline of the HD sequence and pasting into the NTSC sequence, then removing the attributes. The video is still distorted, lengthened vertically.
2. Using Easy Setup to create a new NTSC Anamorphic sequence, then copying in the edited clips from the timeline of the HD sequence. The video is not distorted vertically or horizontally, but it does not appear correctly. Only the inner section of the video displays -- it's as if the frame has been zoomed in on every clip. If, however, I pull one of the clips from the bin directly into the new NTSC Anamorphic timeline, the video appears correctly. It does not have black letterbox bars, but simply appears widescreen as it did in the HD sequence.
Does it sound to you like starting over is my best solution?
Before I do, I'd like to confirm that I will be able to export a copy using these settings and burn a DVD that will play on standard TV.
I tried exporting the NTSC Anamorphic sequence with the one correctly-appearing clip. I used QuickTime Conversion and tried setting the size at each NTSC 720x480 4x3 and 768x576 SD with the "Preserve aspect ratio using letterbox" option checked. However, each time this created a movie that was both letterboxed and lengthened vertically -- as if the black bars at top and bottom are not wide enough.
Do you think NTSC Anamorphic is the best setup for this size video?
Thanks again!