That sounds about right to export via FCP to quicktime at current settings. If you want to deliver in quicktime you need to change your settings to make it smaller.... the HDV after the export doesnt look very good anyway.
As far as creating a DVD, the best way that we have found to do it is to export from FCP to uncompressed HD 10 bit then plug the MASSIVE file into Compressor to compress it to a DV file for DVD. Ends up taking a long time, maybe 3 hours for a 5 minute piece (all together) but it looks GREAT!
We have a Kona card, which gives us the codec for the 1080i uncompressed 10 bit export, but I think there is an option for that in FCP as well....
Hope this helps.
Nick Inc -
http://www.reelinsyte.com
FCP, Dual 2.7 G5, 4GB RAM, KONA LHE