I had seen someone else recommend blurring the whole footage a bit. I have way too many text objects to apply blur to all of them (lots of chapters with nested sequences with lots of After Effects animated lower thirds). If the client feels test is too oversharpened I can circle back and give it a try. My co-worke says she can't notice it at all so it may be me working on it at the computer makes it more noticeable.
I really hate to "dumb" down the master HD source project though because I need to make exports to other formats too like Windows Media where that blur is probably unnecessary. Obviously I could make a copy of the whole project or duplicate sequences, but there are so many ongoing edits I fear I'd wind up editing two project files.
Also, the font is part of the finalized visual identity scheme so I can't swap it out.
Thanks for all your help today. If anyone else has experience with Premiere Pro and Sony DVD Architect I'd love your tips and tricks too.