Quicktime moves from FCP

Ok - I'm officially out of my depth.
After 6 months editing a lorryload of 4x3 miniDV interviews I finally got sign-off this morning.
Client wants a quick DVD to watch over Chritmas, so I Export Quicktime movies (normal, no conversion) of all 10 timelines, simply adding .mov on the end.
I make a 4x3 DVD project in iDVD, and drop in the QT moves.
All fine and dandy, but one, just ONE of these movies insists in playing all squeezed out in 16x9.
The odd thing is that this is the second time I've done this. Last week I went through the same process, and the same clip was playing out in 16x9.
These are all new clips (I've changed the edit since then), and it's a brand new iDVD project.
But same result.
I've checked the rogue clip in QT and iTunes, and it plays just the same as all the others.
So I tried MPEGStreamclip - and noticed some full screen red rogue frames, which suggested a problem.
I checked the other clips - they all have the red rogue frames - even though they behave normally in iDVD.
What might be causing this?
I'm tried re-Exporting all the clips as 100% Quicktime movies from Streamclip.
The files were all much bigger then the originals. How can that be happening?
But when I reload them in Streamclip they still have the red flashes.
I've tried doing a SaveAs from Quicktime - still red flashes.
Even MPE4 versions - red flashes - and these show up in iDVD too.
Any advice gratefully received. I'm running out of time here
Thanks
Tom

I forget to mention that I made the original movies on a MacBook Pro running Tiger and QT 7.6.4, but was trying to make the iDVD on a new machine running Snow Leopard and QT10 - because it has a much faster burner and I'm in a hurry!
I'm now trying to make the iDVD on the older machine and there is no sign of the red flashes - plus that rogue movies plays normally.
Phew... BUT
Someone else is making the real, proper DVD - what will happen when he tried to pick up these quicktime movies on and AVID (pre version 5)?
Thanks
Tom

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