Hey Hal,
Have seen thefirstt half of this and loved your editing choices and pace.
I would like to throw out that i also struggled with getting the 1080p version to work - despite being technically bluray compliant, i was unable to get any of your pt edits to work successfully on a bluray disc,
My suggestion for you, if you don't already, is to render your final project to a lossless file that you then encode to the different release formats. Should save time.
My personal preference is to encode my blurays with bdtoavchd. I set it to very slow and tune grain ( in advanced) and let it fly. Beautiful results every time.