Explicitly doing a "render all" does nothing, and also auto render doesn't ever kick in either, so that seems to suggest that everything has been rendered. Also, as far as I can tell, everything is in HDV1080i format.
Oh! I bet I know what the problem is: There is a mismatch I'd forgotten about: 44.1KHz audio (in the Sequence Settings for the sequence I'm exporting) vs. 48KHz audio in the "Audio/Video settings" in the FCP menu. But more complicatedly, the FCP sequence contains a mixture of 44.1KHz and 48KHz audio.
44.1KHz audio crept in the mix when I imported some background music from CDs. Now autorender in FCP would convert it to 48KHz, but whenever it did so, an apparent bug caused it to playback monaural. More precisely, it would still be 2 stereo channels, but the two would be identical, presumably an error in the 44.1KHz->48KHz sample-rate conversion code.
Now, as it turns out, is export finished a lot faster than originally predicted, but it was still around 4 hours or so. However, when it completed, I found that the resulting audio and video are out of sync! Please see
Gary Morrison, "QuickTime Export: AV Out of Sync", 03:16pm Aug 21, 2005 CDT for more description.
Maybe this is also an anomaly caused by the mixed sample rates. I'll try using SounndTrack Pro to convert the sample rates. Hopefully it will do that without turning it monaural.