Problem exporting large sequence in Premiere Pro 5.5

Question

So I am currently creating a compilation of many videos for a contest this weekend, and am having trouble exporting it all together.
This is a mix of SD and HD footage, from various framerates, resolutions and aspect ratios that I have conformed (using the "Scale to Frame Size" option) to a 720x480, 4:3, 29.97 fps, progressive scan environment (started with the DV NTSC preset and modified from there).
The project has expanded to become 1 hour and 45 minutes long, with many titles (at least 58). I should also note that it appears to have become very unstable, crashing quite frequently, though other projects will load just fine. And before anyone asks, I have already attempted moving everything into a new sequence and exporting from there, as well as importing the sequence into a new project, to no avail.
My normal export settings are:
720x480 resolution,
4:3 aspect ratio,
29.97 fps,
Render at Maximum Depth checked,
VBR,
2 pass,
Target bitrate: 8,
Maximum bitrate 12
I should also note that I have not prerendered any of the footage.
Now, whenever I try to export it begins the process, and then always hangs at 18%, when the m4v file has become 2.15 GB, and then even after leaving it for several hours it progresses no further, and the file size of the m4v and others does not change. I have attempted a new export now that runs with
VBR 1 pass
Target bitrate 3
Maximum bitrate 6
to see if that changes anything, though I don't expect it will.
Please get back to me about this as soon as possible, as an event this weekend is riding entirely on my ability to create this video.

Answer 1

Never leave empty gaps in the timeline, fill with black. File > New Item > Black Video will create a slug you can use.
When I mention Media Encoder, I do mean exporting direct from Premiere - that is just an integrated version of AME. If you choose "Queue", that then opens AME as a stand-alone app.
Advice on check boxes - boxes that are unchecked by default are in that state for a reason - they only help in certain situations, so if unsure what the result might be, stick with the defaults. For instance "Max Render Quality" sounds like a no-brainer, but in reality only helps when scaling the output. If exporting 1080 to 1080 for example, then no need for that.
In another thread today, someone had poor quality video output and it was a direct result of checking the "Frame Blending" box - for reasons unknown ;-)
Thanks
Jeff Pulera
Safe Harbor Computers