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At that point, I've got a ReplayTV-format MPEG file minus the commercials

Does it use the ReplayTV commercial markers, or let you graphicially edit them out yourself? I have found the replay commercial skip to be nice, but not 100%, thus I need to manually edit.

The next step beyond that is getting the files into a DVD burnable format complete with menus. This is typicially where a transcode comes in beyond my control trying to use either iDVD (after first having to transcode to DV first), or with Toast (Where whatever "encoding" it does manages to make a DVD hold maybe 60 minutes and look bad.)

I have no interest in doing this on a Windows PC, as my Wintendo and Media PC lack DVD burners. If I invest in anything, it will be software that does what I want on the Mac side. How well Fian Cut Express does is beyond me, but for now that seems a bit extreme for simple cutting of video. That, and $300 later, I still would have the DVD problem.