Thanks for your detailed reports. Very interesting.
In one, you said:
I checked my audio clips and found they were already AIFF except for one.
Not sure I understand you there. Did you find the AIFF audio clips in the Media folder, or find that your iTunes music files were AIFFs? (iTunes lets us import music to iTunes as AIFFs.)
It's normal for iMovie HD to convert iTunes music files to AIFFs as our songs are imported to iMovie HD, so a Media folder would normally contain those AIFFs. At least one user found, however, that replacing her iMovie-created AIFFs imported from iTunes with AIFFs imported from an Audio CD solved her playback problem. Something was different about those AIFFs.
So although the audio files in the Media folder are AIFFs they may not work as well as AIFFs imported from an Audio CD. That's not to say they are causing your playback problem, they don't seem to be. But I suspect they can SOMETIMES cause a problem.
(The maddening thing about this playback problem is that there seems be multiple contributing factors, sometimes working together and sometimes independently.)
About the extracted audio. If lots of extracted audio clips can contribute to playback problems, which I suspect they do, that may be related to HOW iMovie does it. When iMovie extracts audio from a clip it duplicates the audio from the clip's ENTIRE Media file, then mutes the audio of the selected video clip. So if a Media file contains a 30-minute scene, and we split the 30 minute clip into two clips, one 1-minute clip and one 29-minute clip, extracting audio from the 1-minute clip extracts 30 minutes of audio.
More typical, let's say we split the 30 minute clip into 10 clips, each 3 minutes long, then extract audio from each of the clips. Now the project will contain 10 AIFF files, each 30 minutes long. When playing the project iMovie must open and close numerous AIFF files and juggle which part of each file to play. And, quite possibly, adjust the volume while doing it.
I'm quite certain QuickTime/iMovie is theoretically able to do that, but if there's some factor affecting efficiency, it might not do it smoothly. (A slow disk, or full disk, or a permissions problem might cause inefficiencies, for example.)
It might be more efficient to extract the audio of the entire 30-minute clip just once, THEN do the necessary clip-splitting. If we split a clip, then without moving the playhead split the extracted audio clip below it, then Lock the audio clip, it will stick to the video clip as we drag the clip elsewhere on the Timeline. That will reduce the number of extracted audio files, which MAY simplify iMovie playback. It may be possible to have our extracted cake and eat it too.
If it's not all too obvious, this is all speculation for I've never had a playback problem here to test. Acquiring a few troubled projects may help end my endless speculation. 🙂
Karl