I have experience the same maddening BUG with audio on export. Like other posters have said, the problem seems to be with speed settings. My project messes up with ANY speed adjusted clip, whether it be custom or slider.
On the phone with Apple support today, and they said even after you delete a clip from the project file, iMovie still retains some info in the database file for the project. They were unable to help me with a fix (no surprise there)
Just to clarify, the fix is
1. Don't use speed adjusted clips (i sound like a PC user!)
~~~~or if you have to
2. Figure out what clips you want to speed adjust, stick them in their own project file one at a time, adjust the speed, export at highest quality, and then import the sped up clip into your original project file. A pain, but it does work.
The phone support at Apple also said "when you detach the audio, and delete the video footage, the project file still retains the original video footage but puts a "video mute" command on it". He said that the best result would be to do all of the audio in garageband.
That is not acceptable.
Other problems with iMovie seem to come from how it (doesn't) handle different file types. If your iMovie is slow, with lots of spinning wheel, try the following:
1. close iMovie
2. hold down option key and launch IPHOTO
3. create new iPhoto database. call it "empty"
4. close iPhoto.
5. launch iMovie. notice how much speedier it is.
whenever you work with iMovie, use the empty iphoto database. you can switch between iphoto databases by holding down the option key whenever you launch iphoto. you don't really browse iphoto pics and video in iMovie, do you? according to apple, iMovie cannot readily recognize all of the same formats that iPhoto can. So if you have a lot of videos in your iPhoto database, it takes up a lot of resources trying to sort them out.
while i'm on the subject of posting imovie hacks and fixes and workarounds, here's another one
if you have a Flip HD camera like I do, and detach the audio, iMovie makes it left channel only.
1. prior to detaching the audio, use the "convert clip" command.
2. Once iMovie is done converting it, detach the audio
3. and enjoy beautiful stereo sound from the Flip's awesome bi-directional mic (it's not
that bad)
hope this helps someone. this comes after 6 months of using iMovie on a weekly basis. today was my last project and i hope i NEVER have to use iMovie again.