Using Moyea Blu-Ray Video Converter Ultimate, I can now rip blu-ray discs to compatible 720p format playable with the EVO native player. Once I confirmed my settings produced playable 720p file, I tried to create entire movie "The Replacement Killers" in same format. The first file size limitation I ran into is the micro SD chip, which would not even let me copy a file larger that 4GB (confirmed). The second file size limitation problem appears to be the video player on EVO. I managed to get entire movie into file just under 4GB, copied to EVO, but wouldn't play with same settings as smaller file that did play beautifully. So it appears we are chasing the same file size limitation and I should have answers in a few hours (takes time to create test files of different specific sizes to do validation, buy Moyea has great feature where you can watch the file size grow to a point and simply click cancel, the MP4 simply ends at the point you clicked cancel, brilliant). I will break in half to 2GB chunks as suggested first and go from there. By the way, here are the settings that create amazing MP4s for your EVO right from blu-ray disc. I decided to use "The Replacement Killers" since it has a lot of action, good sound and I own it on both DVD and Blu-Ray so I can compare. I have also confirmed that these play awesomely on large Sharp Aquos via HDMI at 720p with good sound. So at a total size of around 4GB for a Blu-Ray movie, even if it has to be broken into smaller chunks, means I can probably have around 6-8 720p quality full length feature films on single 32GB micro SD chip.
Moyea settings:
Video
H.264 HD Video(*.mp4)
Codec: h264
Size(pix): 1280x720
Bitrate(kbps): 6000
Frame rate(fps): 30
Audio:
Codec: aac
Sample rate(hz): 48000
Bit rate(bps): 320000
Channels: Stereo