It is a fairly simple process, but I admit is does have a couple of parts.
1. When completed, I have Mythtv place a copy of the recording in a directory along with a file containing: showname, description, TV rating, etc.
2. On a schedule, I have a shell script (OS X is just Unix behind the pretty gui) that does most of the work:
A. move the content (both SD and HD) to my Mac.
B. Push the video through a hardware (USB) H.264 encoder chip.
C. Use an open source program to add the program details (show name, description, TV rating, etc) along with a screen shot of the show title to the MP4 file.
D. Add the new file to iTunes.
3. Voila, I have a very nice named and categorized video entry in iTunes that looks just like content the DRM content you purchase, but without the pesky DRM.
This pulls down about 23 shows a week. Completely automated and has been running for well over a year.
I do a similar thing for DVDs using programs called Handbrake and Metax but it is still a manual process.
I encode everything to the max quality the AppleTV will support, unfortunately, iPhones and iTouches can not handle that content. For content I want (or am requested by the wife) to put on a phone, I push the video through the hardware encoder chip a second time with an output setting that is supported by the iPhone.
No, there is no way to officially sync content with the iPhone without going through iTunes. There are solutions for jailbroken phones, but I do not feel the need to use them. iTunes is not that bad. I have never run into a situation where I felt restricted by it and it allows me to consolidate and manage all of my media in one place.
I just looked and my iTunes library has 1.11TB in over 2500 files. It does not miss a beat. If it can manage and stream that much data successfully, how bad could it be?
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jayson