Print to Video - freeze and lost sound

Hi,
I'm using a Mac Pro and FCE HD 3.5 with a La Cie 250 GB external drive attached through FW 800. The whole thing is attached to a Sony DSR 11 deck.
Everytime I try to print my (six minute) project to video, it runs for about 4 minutes and then freezes at exactly the same point. Then after a couple of seconds, it starts up again but with no sound. At the same time, I hear the La Cie drive whirring and then seeming to power down (but I'm not sure). I have done a disk repair on the La Cie and it's verified etc.
I checked the shot where the freeze occurs and it seems OK - it's about 300 MB large, no movement, no transitions or color correction or sound filters etc applied - just a straightforward shot. The file does not seem to be corrupted (but is there any way of telling?)
When I play the project in the timeline it runs fine. I have done all the necessary "render sequence" and "audio" renders, even each time before print to video (even though it does not seem to need rendering).
I also exported the projected to Quick Time and used the QT to try and print to video but with the same result.
The strange thing is that another sequence in the same project that is 8 minutes long, prints to video perfectly.
I am totally mystified by this and wonder if anyone can help me.
Thanks!

Before you go off & spend money, are you absolutely sure you have actually rendered everything & mixed down your audio?
Sequence > Render All > Both
Sequence > Render Only > Mixdown Audio
Also, for what it's worth, I have encountered enough problems with Print to Video that I have taken to just playing from the timeline when I want to record on an external device, and not bothering with PrintToVideo.

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