After several months, I have arrived at the following TV cap procedure
Capture ATI MMC 7.5 MPG2, I-frame only, motion 99, bitrate 9000-12000, res 720x480 or 480x480. AVI's too big for multiple captures.

Demux video with TMPGenc tools

Convert Audio to WAV with FLASK

Use DVD2AVI on video stream

AVISYNTH script w/mpeg2dec to read d2v file, usually resize to 352x480, 352x240 for cartoons, and run IVTC if applicable

open AVI script in vdub, add WAV file, edit carefully, then framserve using Direct Stream copy

CCE 4-pass at between 1200-1800-2400 and 1600-2200-2800

framserve same file to toolame (TMPGenc frontend)

Pulldown.exe to set 2:3 pulldown flag

Mux w/bbMpeg, using maxfilesize to split

VCDImager to make bin (this makes FF and RW work)

NERO to burn
With Digital CAble input, this produces good results, w/good synch, it just seems a little convoluted. Any suggestions to simplify?