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Hey DMK,
Have you tried doing a single-pass encode? Assuming you're running everything through the wizard...
On the last screen, uncheck the 'Start encoding when I finish' box. Click 'finish', and this will close the wizard and bring you to the main screen. Once there, click on the 'properties' button. Once in the properties window, click on the 'compression' tab. There should be a box at the bottom called 'two-pass encoding'. Make sure this box is unchecked, and then hit 'apply settings.' Once settings have been applied, click on the 'start encoding' button.
I've had the same problems with two-pass encoding, and instead of trying to figure out why I just bypassed it altogether! Hope this works for you!
Scott
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