"Could not create ac3" error when burning Blu-ray

I've spent the last week designing a Blu-ray in Encore CS5.  Upon burning, I was given the error message "Cannot create '_sessionfiles_Dsf_session_1_audio.ac3", and the burn failed (after going for seven hours).  I really don't even know where to begin with this.  The Blu-ray is about 80% full (20 GB) and includes multiple timelines and several menus (one of which has audio).  No pop-ups.  It should be a fairly straightforward project.  However, it's given me problem after problem and has taken way too much time.  Can anyone offer insight before I spend another week tracking down the problem?  Thanks.

In the last few days, things have gone from bad to great and back to bad, and it's been non-stop work.  I freed up a ton of space on the computer and backed it up.  Then the computer gave me a kernel panic, which happened so often that I had to restore the whole computer.  I don't know if that's related to the Encore issue.  Then I tried to burn again, and it seemed to be working until it gave me an error message that said "Blu-ray Error: 'device error', code '3', Note: ".  So I looked around online and decided to export as an ISO disc image file.  That worked fine.  Then I tried burning a Blu-ray using third-party software, which failed halfway through.  Next I tried burning using Disc Utility.  It got all the way to the end and said "Could not verify" and failed.  I tried playing it in my Blu-ray player anyway.  For the first time, it actually worked.  The movie and the Scene Selection menu work fine.  But when I try to go to Special Features, nothing happens.  The Blu-ray is supposed to go to the Special Features menu at the end of the main movie, but it just goes to a black screen after that and locks up.  Now I'm really lost.  Any more suggestions?  Thanks.

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