15 minute, 400 meg project too big for one DVD?

I have a 15 minute video in widescreen format that is about 400 megabytes in size according to the project info.
When attempting to burn, I am told that the project size is too big for a DVD and suggests I use a dual layer DVD.
I have over 390 gig available on my 1 TB hard drive.
I have no chapter markers
I have reduced the intro clip(s) to less than 30 seconds.
All to no avail. I am now burning the dvd using Toast, which is perfectly happy using 400 megabytes of my DVD to burn the disk.
What assets could iDVD possibly be adding to use up the remaining 4 gig of disk space, and how might I view them and delete them?
I know this is an old topic...I've read lots of posts including one similar to mine. In most cases people are attempting to burn over 1 hour of video. In the one case similar to mine, the person had full length video in each chapter marker (or some such issue). I have none.
In my case it is a 15 minute video (granted its in HD/widescreen format). Why, with a project size well under the disc size, does it refuse to burn due to size limits? Clearly the project info does not reflect iDVD's actual size requirements for the project.
Why not?
Finally, changing to 4x3 is not an option and yes, I have tried changing the compression algorithm from best performance to higher quality, though this is supposedly for video longer than 60 minutes.

Hi
Free space only referes to Start-up (boot) hard disk. iDVD can't use any other for scratch files.
25Gb is my minimum setting.
15 minutes video - to much indicates that it might have been droped it into iDVD window
but here landed it into a "button area" - not movie area.
Recommendation in case of this is to move it out (or start a new iDVD project)
and in iDVD use the Import function instead. Now it lands where it should.
And dep on Your encoding choise the movie can be up to 60 or 120 minutes long
(menu included => simple menu = more movie)
Other alternative is feeding iDVD strange video formats that can give many
interesting problems eg .wmv, .avi, .mpeg4 etc.
Yours Bengt W

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