OK... I think I have finally devised the perfect script.

The plan was to create ONE script that could be used relatively well for any type of program captured from television.

This means cartoons, movies, programs....
The captures are all coming from ReplayTV.

They are 720x480 Interlaced NTSC analog cable source. The MPEG files are a constant bit rate and a slightly strange MPEG source.
DVD2AVI works great

and then I take my .dv2 file and use Movie Stacker to take it to 480 x 480.

(I am using the KVCD3 template). 352 to too dull and 528 does not buy any extra quality I can see.
Here is the fun part. This is the script I have come up with:

:P
LoadPlugin("C:\KVCD\Versions\AviSynth2\plugins\MPE G2Dec3.dll")
LoadPlugin("C:\KVCD\Versions\AviSynth2\plugins\Dec ombLegacy.dll")
LoadPlugin("C:\KVCD\Versions\AviSynth2\plugins\Gri pFit_preview.dll")
LoadPlugin("C:\KVCD\Versions\AviSynth2\plugins\Blo ckBuster.dll")
LoadPlugin("C:\KVCD\Versions\AviSynth2\plugins\Dus tV5.dll")
LoadPlugin("C:\KVCD\Versions\AviSynth2\plugins\Leg alClip.dll")
LoadPlugin("C:\KVCD\Versions\AviSynth2\plugins\Cnr 2.dll")
LoadPlugin("C:\KVCD\Versions\AviSynth2\plugins\STM edianFilter.dll")
Mpeg2Source("xxxx.d2v")
LegalClip()
FieldDeinterlace()
Cnr2()
GripCrop(480, 480, overscan=2, source_anamorphic=false)
GripSize(resizer="BicubicResize")
STMedianFilter(8, 32, 0, 0, 8, 32)
PixieDust()
BlockBuster(method="noise", detail_max=7, variance=0.5, seed=1)
GripBorders()
LegalClip()
I am not making it up when I say I have invested over 100 man hours tweaking and testing. I have gone through 200 CD-Rs. (My girfriend is sick of my floor being covered with test VCDs).
I have tested each filter in different places in the script and I have taken most of my ideas from KWAG!!!!, the AVISYNTH site and the DOOM9 formus. (I am not nearly as smart as those guys!).
This is not the fastest script. On my Athlon 2200+ (1GB RAM) it takes about 90-100 minutes per 30 minute show.
But the results are excellent.

The original captures are a little noisy. An Episode of The Simpsons I did last night looks better than when it was on the first time. I did several episodes of "Good Eats" off Food TV and the only problem was when there is significant amounts of bright white text on the screen there is a bit of noise or shadowing around it. Nothing to complain about.
The file sizes are very small.

I am able to get 80 minutes of The Simpsons 60 minutes of Good Eats on a VCD with plenty of room for other fun files and clips (for my interactive menus).
Next I am testing Hi8 captures. If those work too...
I could not be any happier. Thanks to all for the massive amount of help.
(Of couse I am NEVER above more suggestions).
The reason I strayed away from the current optimal scripts was they were a little too blurry on my 35" Sony Trinitron. It is not HDTV and the source is not sharp enough to handle the extra smoothing.
Grantman
P.S. Thank You, Thank You, Thank You, Thank You, KWAG!

A quick count showed more than 20 posts you answered or added to for me that basically gave me the info I needed. Then... last night I came across a post from JAN 2003 where you SansGrip were testing Dust and Temporal Smoother.
http://www.kvcd.net/forum/viewtopic....g2dec3&start=0
That did it.

The final piece was in place. As Mr. Burns would say:
"EXCELLENT!"