CS4: DVD encoding problem(s) Mpeg2 and avi

Hi,
I have been trying to burn my video files to DVD. After a month of failures and 50+ wasted DVDs thrown in the garbage -- plus countless hours trying to learn the basics, reading the FAQs, trouble-shooting, and losing my patience awaiting technical replies from Adobe (which I now suspect will go unanswered) -- I am out of solutions and waving a white flag.
Problem:
I have two video files. Both were created in Premiere Pro CS4 and exported via the Adobe Media Encoder as MPEG2-DVD high quality files (for NTSC) .
The first Mpeg2 file is 800 MB (41 mins); the other is 988 MB (50 mins).
I have placed the two files into a single timeline, with 21 chapter stops.
The only other file in the entire project is a PSD file for the Menu. It has two buttons, which link respectively to chapter stops 1 and 10.
My results are failure-upon-failure...
Primary question:
When I go to "Build" the DVD, it says the Encoded Size is 4.7 GB ~ same size as the DVD. This displays in the "Disc Info".
Similarly, when I open my "Timeline" properties for that single timeline, it says the duration is 1 hour 31 minutes - 4.7 GB.
Why is the disc a full 4.7 GB when the two video files (combined) are under 2 GB?
Supplementary questions:
My "Flowchart" and "Property" links display the Menu, with the two button links in my Menu PSD connecting to the respective chapter stops.
There are no problems when I click "Check Project," and the project works perfectly in "Preview" mode.
But, when I attempt to test the burned DVD into different DVD players, the Menu doesn't appear and the play defaults to random chapters, then freezes. I can access the menu, but only after the play has started and/or frozen, and I have to do that by clicking the "Menu" button on my DVD remotes. And again, when I hit play on either of the buttons on the main menu, the video files will freeze, which means burning & testing each disc sometimes takes an hour per.
Does anybody have a solution?
I have read and watched several tutorials, to no avail. I have tried burning the Project using large Mpeg files as well as medium Mpeg files, both encoded with 1-Pass VBR, 2-pass VBR, CBR. I have tried widescreen and normal.
I have also tried using AVI files. The two AVI files are respectively 41 mins @ 1536 kbps 720x480 8.68GB; and 50 mins @ 1536 kbps 720x480 10.6GB.
Together, those two AVI files are 19+ GB, which would require 5 DVDs.
What am I doing wrong? What should I be using to burn DVDs - Mpeg-2 or Avis?
When I export from Premiere Pro/Adobe Media Encoder, whould I be exporting as Mpeg2 files or Mpeg2-DVD?
Is it possible that Encore automatically expand and/or compress files, so that the 19GB avi is compressed to 4.7 GB DVD; and the 1.8 GB Mpeg2 "expands" to 4.7 GB?
Any help would be greatly appreciated, as this project has caused me numerous delays and ruined deadlines and soured me even more on Adobe's video editing product and their truly-awful customer support.
Thank you

As far as the use of premiere pro CS4 with Encore Cs4, do not bother to pre transcode your material.  Let Encore do this for you.  Leave your files in the original format which I assume was AVI.  Instead import your Premiere Pro sequence directly from the project (or export it from Premiere Pro it to encore).   As you quessed Encore will try and expand/compress your files for the DVD you are making.
Encore by default trys to transcode for the best quality that will fit onto the media you specify which is why it is setting the output to 4.7 rather than the file size of the video.
You were not specific enough about the nature of the failed copies.  One thing to do is to always try testing your project from your first menu to see that it behaves correctly.  If you don't want your DVD to start playing automatically make sure you set it to open the Top Menu.  Then try a test either to your hard drive (if you can), or to a RW DVD.
Message was edited by: tnsprin

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    PicknatariMessage Edited by Picknatari on 07-20-2008 07:3 PM

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