Missing Audio from Quicktime Movie Export

I've exported a Quicktime movie from FCP 6.0.4. It's an infomercial show so the call-to-action is a nested sequence on the main sequence timeline. When playing the Quicktime movie, the audio drops off in several 2 second bursts right in the middle of the show during the call-to-action. When played directly from the timeline, the audio is there fine. Early in the show, the same call-to-action nested sequence does NOT drop the audio.
I dragged the audio clip to a new track (one track above) and then re-rendered and re-output to a Quicktime movie. The same audio drop occurred in the same place again. I then marked an In/Out just for that small segment in the timeline and re-output again to Quicktime and the audio is fine.
My final Quicktime movie size is 150 GB (gigs) because it is full HD, uncompressed, 8-bit 4:2:2, and 28:30 long.
I've had a HORRIFIC experience the past 3 months just getting files to render properly and stay connected. It baffles me why Apple is working on SO many bells and whistles for FCP without having mastered their basic file management. It makes me want to check into AVID to see if they can at least give us the basics competently.
Thanks for any advice on this - I'm going to try to render out now in smaller segments and then patch together. Sad...

Make sure you do an audio mixdown. The manual explains the process.
x

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