Thanks for those replies, very useful I dont really know much about video encoding. Just fancied putting stuff on SD cards and output to telly.
I got one of them cheapy viking rebranded cards for £15 so it probably is slow. It's ideal for all the games I have on there. But I dont understand if it was a slow SD card why would it play ok once it had buffered. Why does it need to buffer so much? There is only 64Mb internal memory so it shouldnt take 10 minutes to do that. Is it really this or just a bad mplayer?
I will give re-encoding a go and see if I can reduce the file size. For some reason it didnt scale the video so that's one thing to look at. I am using Linux, btw, so there doesnt appear to be many GUI freindly video apps yet. I have found one or two. I havnt had a chance to look properly for pockedivx. I used ffmpeg and mencoder. I tried to use ffmpeg to convert an flv file of the two ronnies sketch 'Fork Handles' but it had no sound and was missing frames. So I have a lot to learn here.
Have to get back to the tv to 'finish' watching the producers. my god is soooo crap. I hate musicals. It's the missus' choice. Luckily I have my little budy now to see me through the hard times