Hey Mark,
Congrats on the new gig! Rock on!
RE the website -
the last year's been a long slog that flashed by in a trice! At the minute, though, I've gotta 15th October deadline for version 2007/8 of an old client's promo vid due for release at DEMA... Have spent the last year tied up between work and learning loadsa new presentational tricks (all will be revealed in a demoreel soon) and have promised myself some "personal" time to now push out a whole new promotional campaign of my own!
Should be looking for beginning of November or so kickoff. Will have the last couple of clients' HD promo vids on their, a Sipadan special, and - of course - the demoreel... I still owe MaryLynn a video from a year ago! If you're reading this, ML, gimme til new year, yeah?!?!? Anyway, watch this space!
With your FC predicament, I'm still wondering whether or not there's some freaky-deaky setting inside it all that's creating this conundrum...
What path are you following when selecting Export?
The first choice - "Quicktime Movie" - will create only a linked reference file which uses the data from your timeline to locate all of the raw clips and rendered transitions / effects in their folder somewhere on the harddrive. It is only a wee file as it is literally reference code. If you were to drag it to a thumb drive and take it to your mate's computer, it wouldn't open because it wouldn't have all the raw files etc to read from...
The second choice - "Using Compressor - does literally that, opens compressor where you will then setup your compression. Something I only bother to use when needing to batch process a whole load of clips / videos....
The third choice - "Using Quicktime Conversion" - creates a fully standalone Quicktime file which - for
argument's sake is in DVPAL format - will have a DV bitrate and, therefore, reflect your normal expected file size of DV footage.
So... When you say "exporting files as AIC60i files" I presume that you're creating the standalone QT file by using the third choice or when you say "a native QT file" is that when you're creating the standalone?
Sorry to be finickety but I reckon if I can actually visualise your workflow then we can crack this one in no time....
If you've been exporting from FC for a long time, and I've just patronised the hell out of you by giving you some layman's explanations above then I apologise....... 
Anyhows, spell out your workflow and I'll see if I can get you on track again...
TaDa for now,
Chris