Problems 'playing' a project: dropped frames/stutters

For some strange reason, during the last few weeks we've been having a lot of problems exporting projects by playing them via canvas or through 'print to video.' The projects range in size from 8 minutes to 30 minutes. They will play fine on one pass, but then another one will have a stutter. The stutter doesn't occur in the same place each time.
Doubt that the problem lies in the connections outside of the computer (it's going via firewire to a Sony DVCam Digital Videocassette recorder DSR-45, then to a mixing board and to DVD recorder or Beta deck), since the stutter appears on the computer screen (it sometimes is a few frames of black or gray or even a red 'not rendered/media not connected' type screen).
The drive being used is internal (one of two 400GB hard drives, each of which has about 100GB free).
The material is all shot on the same Sony DVCAMs. It's listed as DV/DVCPRO-NTSC 29.97FPS. Only difference I see in sequence as compared to master clips in terms of browser settings is in audio format (master listed as 16-integer as aud format versus 32-bit floating point in sequence)
I've Disc Warriored and Disc Utilitied the computer.
It's a Dual 2.6 GHz PowerPC G5 with 4.5 GB of RAM running 10.4.11 and the latest upgrades of Final Cut Studio.
Can't think of anything that has changed recently (only thing is updating the FCS2 files...which did happen right around the time when the problems started, come to think about it)
Any suggestions would be appreciated

Few more things to add:
I just exported one of the problem projects to DVD using compressor and it worked flawlessly. Also, the glitches occurred regardless of whether or not the project is in the 'working' stage (with layers, overlays, etc that have been rendered) or has been exported as a self-contained Quicktime file w/o any compression, using same settings as project.

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