I didn't get the part about opening VIDEO_TS folders from your original post, thus my assumption you had problems with the SuperDrive.
Yeah sorry, im testing as im posting. Turns out Front row won't open video_ts files anymore either. it must be asking dvd player to do the legwork.
i havent tried resetting smc, i tried resetting nvram to no effect. I'll try it as soon as this final test rip finishes.
Why don't you transcode the videos to a smaller size then?
I have plenty of space, if my drives fill up i'll happily build some more 4TB HDDs, thats not a problem. Also, ripping is short and sweet, no extra transcode time, or bogging down my computer for an hour whilst it transcodes. Plus it maintains full DVD quality with chapters and all the metainformation (i know we can do chapters now in the mp4 and mkv containers but thats again an extra step). The only real advantage i see to transcodes is disk space savings at the cost of time and a little quality - since i have no disk space issues (or time to spare!!

) i'll stick to video_ts. unless of course there's some other advantage i haven't considered?
thanks for your help so far spinnerlys, do you have any other ideas?
or anyone else out there with the mac mini and an external superdrive? or maybe macbook air owners? perhaps even macbook pro owners who've put in an optibay mod?
i don't mind buying another dvd drive over the superdrive if it'll get the job done .. but before i spring for another drive i'd like to know the problem is specifically with the superdrive interacting with the os, and another external dvd drive wouldn't just succumb to the same problem. anyone have exactly the same problem as me and fix it by using a different drive?