Didn't see it mentioned earlier, but what did you do to fix the saber shots? Replace them with older source material, or actually re-rotoscope the shots? Just curious how much you've dived into the process.
BTW, you may want to hold of on re-doing TPM until the HD transfer comes out (whenever that ends up being). For now, the less-than-ideal transfer that we have will be my basis for DVD until the HD/BluRay debacle is settled and the hi-def format is standard.
--ADM