Preview in iDVD fine, audio drops off in data image or burned DVDs

Playback in Final Cut HD Express and iDVD preview works perfectly. I create a DVD image and the audio drops out the last minute of a 39 min program. The movie file source in iDVD is DV/DVC Pro. I did a Quicktime conversion from Final Cut using High Quality H.264 and the audio remained but the quality was awful. I did a program info in iDVD and the DV movie did not eat up too much space in iDVD so that's not an issue. I have 28 avail. GB in my external drive where the project is located so not an issue.
I have 23 GB left in my internal drive so that wouldn't be an issue either.
The Apple Store techs were stumped.
The audio that goes missing in the data image and a DVD I burned was a fade out done on Final Cut. There is a blue line on the timeline, but if that was an issue then it wouldn't play back in iDVD. It DOES play back perfectly in iDVD. Somewhere in the conversion from iDVD and a data image or DVD messes with that audio. Any hints?

No definite suggestions, except for things to try (might they count as hints?):
Before exporting from FCE, did you mix down the audio? (Sequence>Render Only>Mixdown).
Did you export a reference movie, or a self-contained movie? Whatever you did, you might try the other.
What versions of FCE, QuickTime, iDVD? Some recent QT updates have caused strange things to happen in older versions of FCE.

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