Dave -
One weird little tool I discovered for making very small, but very good QTs came with Call Recorder for Skype, made by these people... It's a little suite of drag and drop encoders...
http://www.ecamm.com/mac/free/
If you'll all PC, this won't help, but it's a great little app. I also usually make Animation QT's, then drop them on this and watch as it spits out a much smaller (bit-wise) QT with very good quality. I also have good luck using MPEG Streamclip.
Ron