PAL to NTSC, when to convert?  Can't Build or Burn now.

I shot on a Pal camera and built the project as a NTSC project in FCP 5 (Studio).  Converted all the PAL video into NTSC when compressing using Compression out of FCP. All seemed to work fine.  Built the DVD as a NTSC project, no problems until...  I can't get it to Burn, build or format.  Right now, it is freezing up on build, but I've actually burned a few CDs but none of them have worked. Always crashed the DVD player in my Computer.
Anybody have any experience with this?
Would I be better off going back and finishing the project as a PAL project in FCP and then convert the whole project into NTSC? How to do that??
I've been dealing with thise issues for days now. One small step forwards, 2 big steps backwards.
Especially frustrating because I've been working on this project for years and now it is ALMOST finished, but I can't quite do it......
Any help, suggestions would be appreciated.
Thanks!
Ed

this is my workflow for shooting in PAL for NTSC DVD discs - it has worked well for a contract to USA clients for over 6 years:
shoot in PAL
edit in Final Cut in PAL sequence
export QT file - self contained, current settings
standards convert to NTSC using Nattress:
http://www.nattress.com/Products/standardsconversion/standardsconversion.htm
import into Compressor or Bitvice and produce M2V and AC3 files
http://www.innobits.com/bitvice.html
author in DVDSP in an NTSC project
build project
burn disc using Toast with TAIYO YUDEN DVD-R discs
http://www.roxio.com/eng/products/toast/titanium/overview.html?ClickID=cqk44wven vp77zlfpxaqzwqe44w77wwsxkix
http://www.jigsaw24.com/default.aspx?ITEM=JIGSG155APA&IP=5WGSTOCONSC_DISCSPLBDVDFC

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