Can't burn movie over 2 hours

I have a movie that is 2 hr 23 min. In iMovie HD 6.0.4, I added chapters every 15 minutes. When I import into iDVD 7.0.4, of course it says that the project is too big. I change to "Double-Layer 7.7 GB" I also change Encoding to "Professional Quality" or "High Quality" and the Capacity bar says Total: 143 min 4.52 GB & the color drops down about a 1/3. I add a couple pictures for the menus and take away the button pictutes. When I try to burn, the Capacity bar completely fills up, but only says 7.64 GB. The disc does not finish burning before being ejected and will not work in a DVD player. Also, when I save the project, the chapter fonts revert to default & some of the button window panes come back. I can change & save over & over with the same reversions still taking place.
I have tried saving to different sizes. Original file was 6 GB mp4. I have tried getting the file down to 2 GB mov and 1.62 GB mov, but still doesn't work. I tried reducing resolution & bit rate. I have not as of yet tried fps. Is there a particular trick I need to do? What other options can I try? I read that other people have been able to burn longer movies - up to 3 hours?

Hi james - welcome to the discussions.
One reason for this error is that your hard drive is getting full. before DVDSP writes to disc it creates a copy of the build files in a location you specify. Have you got enough room on your drive?
The second thing to try is to encode these movies before you bring them in to DVDSP - this will give you a far more accurate idea of the file sizes you are dealing with. You should certainly be able to get your project onto a DVD-R with such a low bitrate, but you are likely to lose quality doing so. You can also afford to raise that bitrate slightly. If you encode the audio to AC3 you will free even more room for the video and you could get away with 2.5 as a setting... still woefully low for DV material.
Your options are therefore to either use DL DVD-R, or encode using MPEG1, or encode using MPEG2 at Half D1 resolution.

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