Oh! NOW I understand, you're asking yourself what could be the reason that CQmatic didn't calculated the right CQ to fit your stream to one cd.
Well there's no prediction you can totally trust in and will never be. Cause it does not test the compressibility on the Whole movie but on parts of the movie.
So if a script is used (as I assume) can you post it please!
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So you mean I should have a higher audiobitrate like 160kbps and rise the resolution to 704x480 to resirve better quality even if the CQ will not be as high as with 544x480? am I right
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Well in case of CQ 89,77 which gives less filesize to fit one CD (audio included!!! *you will see what I mean*) you really should think about my recommendations as mentioned above.
Even for example a CQ of 70 @ 704x576 will give you a very very good (even better/sharper) image cause it won't be that resized by the player as in the case of 544x576.
BUT we/you calculated wrong!!! ::
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I had no idea the m1v file would come out 130 mb to smal
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In your case of 630MB m1v .... When seeing it with YOUR eyes its even 155MB too small

final size "should" be ca. 785MB
BUT: Please keep in mind that there will be audio added! But 58mins encoded at 128kbit will not result that much!.. the m1v output you received still will give you a too small over all result. ... So script please!