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davebenton said:
I've had no problems as long as my content was under 2 hours. 1:59:40 on the last one with no trouble.
Question for you - do you have motion menus? (I assume that 2 hours includes the motion menus you have). Personally I'm not right on the 2 hour limit, so it hasn't been an issue for me.
 
Long time coming...

I know this doesn't really help MattG at all but I just wanted to back up Makosuke's point about knowing the file size before encoding. Here's the QT Pro MPEG-2 Encoder Options window, notice it shows an estimated file size of 2.4 MB. If I move either of the sliders in the window it live updates to show me the new file size at that bit rate.

So, iDVD should know the file size at the start of the encode...
 

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