Hi Jim,
Do you have any updates on your issues?
It makes me sad to see so many people struggling with Long-GOP MPEG-2 in Final Cut Pro. Issues like these have been the story of my life for well over a year now, and I am starting to get really tired of it. I have tried all the suggested tips and tricks, without any luck. Transcoding to ProRes obviously helps, but for a lot of people transcoding to an intermediate codec is not really an option. It might work fine if you only have a single edit suite to support, but with a large number of FCP systems the storage requirements are quite the challenge.
XDCAM discs are very affordable, and the Sony broadcast cameras, and recently the prosumer XF series, are really quite nice. I-frame based HD MPEG-2 from the NANOFlash seems to be more stable in FCP, but it comes at a cost - You need to at least double or triple your storage capacity. Storage requirements for XDCAM HD422 with a constant bitrate of 50Mbit is a big selling point for a lot of people and organizations. If only editing these Long-GOP MPEG-2 based formats was a little more stable in Final Cut Pro... as you would expect when Apple advertise that they support it.
Any form of HD Long-GOP MPEG-2 is decoded by the AppleHDVCodec.component (located in /Library/QuickTime). The codec is obviously the problem here, as working with other i-frame based media works fine most of the time. XDCAM EX is quite unstable too. After an editing session with HD Long-GOP MPEG-2 based media, you will most likely also see a lot of memory allocation errors (malloc) in the system.log in /Applications/Utilities/Console. This makes me think there are some memory leak problems going on when decoding Long-GOP MPEG-2. As you have most likely already experienced, the worst you can do is mixing other codecs together with Long-GOP MPEG-2 in the same sequence.
XDCAM HD422 support was introduced with Final Cut Pro 6.0.3, in Apple HDV Codec 1.4.
Apple HDV Codec 1.4
This release of Apple HDV Codec provides XDCAM HD422 support in Final Cut Pro.
Pro Applications Update 2008‑01 Release Notes
I do not have any experience with XDCAM HD422 projects from back then, but it seems like some XDCAM HD422 projects have become more unstable after Apple HDV Codec 1.6 was introduced with Final Cut Pro 7.0.3. You might want to try reverting to Apple HDV Codec 1.5 (you can extract it from the AppleHDVCodec.pkg on the Installer DVD using Pacifist). I have seen some projects become more stable after doing that.
Btw. you can analyze your own FCP crash logs, just like Shane Ross did, using Jon Chappel's (Digital Rebellion's) Crash Analyzer, which is part of the FCS Maintenance Pack 🙂