I am trying to help a friend out with FCP, Does FCP have a file size limit for h.264 files? When he exports a h.264 file it crashes as soon as it hits 4 gigs I thought it was a drive format issue but he could export other files over 4 gigs.

Maybe not the answer you're looking for but I always export a Prores file and encode to h.264 in Compressor. It appears to be faster (I haven't timed it) but more importantly it frees up FCP.

If that works you can narrow it down to a bug with FCP.

Thanks Mike thats what I was going to do next. I didnt know if this was a known bug or im doing something wrong.