I have modified the code for version 0.90.4.00 of ProjectX to be able to output files suitable for transferring to the PVR and playing. It is currently here for testing by anyone who wants to.
Download the zip file and unzip into a suitable place. There is nothing else, so you should work it into wherever your current installation is - and just name the two versions differently, or else duplicate the installation and overwrite the ProjectX.jar file. The only difficulty with running in the same place is that the new option is not understood by the old version. Options are stored in a file "X.ini" in the same directory as the jar-file of ProjectX that created it.
There are two added options, both on the "special" settings page.
For writing, select the "add Arion header" option and ensure you have output settings option set to split file at 2000 MB (or a smaller amount if you like for testing). Select your input files and process with the action "to TS" selected. That should give you .AVF and .AVR files ready to copy to the PVR and play.
The file names are derived from the leading parts of the input file name, suffixed with the part number and date as expected by the PVR. ProjectX uses a different naming scheme as the file is being written, but my code just renames it after it has been created.
The current state is...
I have produced playable TS from two sources so far.
The first file was an Mpeg2-PS file that I had produced using ProjectX on a file originally recorded on my MediaStar. It was a small file, but I had split it at 650MB just to test the multi-file capabilities. It played OK, but the fast forward and rewind was rather jerky, and much more obvious that the original (which I still had on the PVR). So there is something about the way ProjectX reconstructs TS files that is not optimum for the MediaStar player. I do not know whether there are options that could fix this, but I am not too interested in trying to fix it, since for me it would just be a lot of trial and error.
The second was a 5.5GB .rec file recorded on a Topfield 5000. So it was already TS format and it played as smoothly as a direct recording on my MediaStar both normal and fast speeds.
Split files: in both cases there was a tiny glitch when the AVR files switched from one to the next. There was perhaps half a second of audio dropped (maybe two syllables), and the video transition was sometimes undetectable. This, I presume, relates to the splitting routine that ProjectX uses. It does not cut off to the file cluster boundary that the Mediastar seems to like. I am currently undecided as to whether it is worth following up. Selecting ProjectX's standard 2000MB split value produces file parts that are just a bit smaller than the "full size" files the MediaStar produces, so that seems to be no problem.
Still not done: