I didn't read every post on this thread, but I skimmed through most of it. I have a couple ideas, though I can't guarantee either. (This post is too long and gets clipped, so I'll post the suggestions one at a time.)
1. The problem may or may not be partially Apple's fault with iMovie. However, I think some of the cheaper DV/analog bridges ("video grabbers") -- and maybe some cameras, too -- may see problems due to not having any embedded audio sync. The way I understand it (which may or may not be right), some players (usually cheaper ones) just play back the audio and video as a data stream and leave it to the software (iMovie) to keep it together. Some of the more advanced models actually include some sort of flags in the data stream to tell the software exactly where the audio and video sync. (Someone please correct me if my understanding is wrong.)
I use the Canopus ADVC-300, which features the "locked audio and video synchronization". I only upgraded to iLife '05 last night, so I haven't tried a long project yet, but it sounds like some people even had problems with iMovie 4, and I didn't, at least with 45-minute projects. You might look into getting a video grabber (or camera) that has the av sync.
I like my Canopus, but I got the 300 because of the video correction options. As I feared, these don't really work as advertised; they tend to either have no visible effect or actually make things worse. If you get the ADVC-110 or 100, you can get all the main stuff that the 300 has (including av sync) but without the video correction stuff, and the 100 or 110 is a lot cheaper. Apple has the 110 for $319, but you can get it on eBay for $235 (buy-it-now), or you might be able to find them even cheaper (especially if they're already used). The 300 is around $435 on eBay. Yes, Canopus is more expensive, but you get what you pay for -- they seem to be really good. (If anybody is really really concerned and considering buying one, I could try a 2hr project sometime soon and let you know.)
Canopus ADVC series:
http://www.canopus.us/US/products/ADVCselection_guide/pm_advcselection.asp