Out of disk space when exporting a 10 min video!

I am trying to export a FCPX project that is roughly 10 mins long. It has transitions, text, music etc. I have a MBA 4gb, 120gb SSD, Intel i5.
The problem is, about half way through it crashes saying that the startup disk is nearly full, even though I have 40gb free before starting.
I have even tried moving all the events and project to an external drive and exporting the file to the same drive but it doesnt make any difference.
The confusing thing is, I exported another file a week early, about 10 mins long and that worked fine. I have the same amount of free disk space as I did then.
Any ideas? Is there a way to set FCP to use the external drive exclusively and not the startup disk?
I am trying to export using the following compressor settings: (It still fails if I use a lower quality export)
Name: High Quality
Description: No description
File Extension: m4v
Estimated size: 2.25 GB/hour of source
Device: Apple TV HD
Frame sync rate: 5 seconds
Video Encoder
          Width and Height: Automatic
          Pixel aspect ratio: Default
          Crop: None
          Padding: None
          Frame rate: (100% of source)
          Frame Controls: Automatically selected: Off
          Codec Type: H.264
          Multi-pass: On, frame reorder: On
          Pixel depth: 24
          Spatial quality: 50
          Min. Spatial quality: 50
          Temporal quality: 50
          Min. temporal quality: 50
          Average data rate: 5 (Mbps)
          Maximum data rate: 14 (Mbps)
Audio Encoder
          Sample Rate: 44.100kHz
          Channels: 2
          Bits Per Sample: 16
          AAC encoder quality: high
          Data rate: 128 Kbps

The problem was an effect I had on one clip. I delted all the effects on all clips and exported without any issues. I then re-applied all the effects and this worked fine also. It was just a correupted effect on one clip that was causing the problem.

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