Disc playback stuttering/skipping on some set top boxes; not others

I have built a dvd in DVD Studio Pro 3, and it plays fine on my computer, small portable dvd player and my region free dvd player, but it stutters a lot on my older set top box I purchased back in the year 2000. I am using the default compression settings of 1 pass VBR 4 low 7 high, and encoded all audio and video previous to import using quicktime and apack. I am using Maxell ink jet printable DVDs that are version 2.0/8X-SPEED DVD-R Revision 3 and can be written 1X to 8X speed. The dvd consists mainly of motion menus that run from 30 seconds to 44 seconds (there are 82), with several short tracks, the longest of which is 3 minutes. This is a dvd menu design portfolio, so the menu complexity was the goal. Total disc size is 2.5 gb.
Compressor won't install on my system so I had to compress each piece of video individually in quicktime...recompression would take 100 hours that I just don't have, and since I'm not sure the bit rate is the culprit (since the dvd plays fine in so many players) I am very reluctant to recompress all the video without knowing definitively that is my problem. I am considering trying some basic apple brand dvds, but don't know if the dvd media could be the problem. I saw on another post that Maxell is considered a reliable brand. I was wondering about dvd speed and compatibility, since the first dvds I bought were too new/too fast to play in any of the set top boxes, and only played on the brand new portable dvd player and in the computer. Any help/advice would be very much appreciated.

I just realized that a few of the specs I posted are mistaken -- I was using the default settings in Apack to convert my aifs to ac3 and it is 448 kbps. They are only 2 channel ac3 files (no surround sound). You mentioned 192 kbps. I can't find any reference to acceptable ac3 settings in the manual. Is 448 too high?
I also realized my mp2s are at the bit rate of 7.5, 5.5 rather than 7.0, 4.0 as I posted earlier.
Do you think either audio compression or video compression could be the source of my problem? Does it make sense for higher compression to work fine on newer players and not on older ones?

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