Disk Image too big in iDVD 6.0.1

I created a 1 hour 27 minute movie in iMovie 6.0.1 and dragged it into a new iDVD 6.0.1 project. Used Travel widescreen theme and the default audio clip for that main menu. Removed the audio clips from the chapter menus. Created a disk image: 4.29GB, which seems big for an hour and a half movie...
Then I noticed a typo. So I deleted the movie from iDVD and dragged my modified iMovie in. Rebuilt the iDVD menus. This time I added a 3 minute AIFF piece of music instead of the default on the main menu. Created a disk image: 4.41GB. Toast Titanium 7.0.2 wouldn't let me burn the disk image to DVD-R unless I used their built-in compression feature; which I did. Looks virtually the same as my original DVD.
I looked at the sizes of VOBs in both images. The main menu VOB (use MPEG Streamclip to find it) was 524.3MB in the disk image that would fit on a SL DVD-R. The one that didn't fit was 914MB. I have to assume that's because of the length of the music on that main menu.
I then edited my 3 minute music to 30 seconds and used that clip. Deleted encoded assets, and re-encoded. That disk image is 4.26GB and squeaks on a SL DVD-R without using Toast compression.
With a movie running only 1 hour and 27 minutes, this "too big" should NOT be an issue.
I did post this here too: http://www.apple.com/feedback/idvd.html
G4 DP 1.25 GHz 2GB RAM 4 Drives 770GB Mac OS X (10.4.6) 2 SuperDrives (SL 8X & DL 16X)

The problem seems to be the same as in
http://discussions.apple.com/thread.jspa?threadID=450944&tstart=120
I also submitted the problem to Apple.
AplleCare did not provide a solution.
I think I have some leads on how to fix it, but no clear solution yet.
PowerMac G4/G5 Mac OS X (10.3.9) iLife06

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Sorry that I can not make a shorter answer !
Hi
Multiplexing error is a very complex problem due to many things (long long list following) - one common but not obvious reason is that material on the iDVD menu goes outside the TV-Safe area (or just touching it).
So first - turn on TV-Safe area and move any object well inside of this.
Wide screen stretched - usually (as I think) it is due to making a 4x3 movie in a 16x9 wide-screen project OR the other way around. This forces one to on flat-screen TV (or other) set the presenting view right - My has 4x3, wide-screen, zoom and auto-wide-screen and I have to switch this by my remote for some DVD I've made "wrong" way.
Now my long long list on Multiplex Error
LONG LONG LONG LIST
Multiplexing Error
PART One.
Use of strange video/audio material e.g. .avi, .wmv, .mp3 etc.
I only use.
Video - StreamingDV (miniDV tape via FireWire) and
Audio - .aiff (as on audio-CDs) (else converted to this .aiff 48KHz)
Photo - .jpg (.bmp known problematic)
Chapters !
A. Using strange letters in video project name e.g. +,/; etc. keep to a-z and 0-9 strange letters in project name e.g. +
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Not in a transition (or within 2-3 seconds from it)
Important when from iMovie HD6 or previous - Now also observed when using FCE 4
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from Robert Modero.
"Multiplexing Error. Problem during initialization of tracks"
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from Boise Jim
Do a safe reboot (by holding down the shift key until you see the spinning gear on gray background, then release, then restart when your start-up screen appears).
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I use only - DVD-R
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Multiplex Error
Chuck, Chicago 2/7/2009.
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3 Chapter marks in transitions - minimum 2 sec from
FROM Bev. (Not a 'guy' but I will answer!)
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by dheb0422
Well, I finally got it, and it was odd enough to post here incase anyone looks this topic up again. Many things were tried, including burning the unedited film, the edited film without titles and chapter markers, abbreviating the chapter markers in case length was the issue (remember the old iMovie used to truncate them when moving to iDVD?). In the process, I noticed that one, and only one, chapter marker was on the same line as the title marker. All the others were on the line above. The only way I seemed able to change that was to clip a few seconds of film. After that last clip, the offending marker took a place on the line above, as were all the others. That run published, compiled completely and burned. That's one for the books.
One user more writes
To add my experience with Multiplex Errors using iDVD (7.0.4), I recently created two iDVD projects
Video from both passed from FCE 4.01 with chapters
One project worked fine in creating disk image file
The other gave Multiplex Errors
I tried suggestions to remove special characters and no chapter marks at beginning, but nothing worked
Note that I've used iDVD for dozens of projects and this is first time I've run into Multiplex Errors
Anyway, for problem project, I tried an experiment where I removed all chapters in FCE and passed to new iDVD project
This time multiplex errors gone
So had something to do with chapters
So now I tried numerous experiments to remove individual chapters and try again creating disk image with new iDVD project
After numerous tries, I was able to narrow problem down to 1 "Bad" chapter mark
That is, when I left the "bad" chapter in my FCE project and passed to iDVD, iDVD gave multiplex error
When I removed "bad" chapter mark (and others in), no multiplex error
As a final experiment, I moved "bad" chapter mark about 5-10 sec's beyond original point and passed to iDVD, the multiplex errors now magically went away and I was able to finally create my disk image.
I have no idea why this worked, but thought I'd mention here in case someone else runs into similar problem.
Rich839
In addition to Bengt's fine advice, burning errors can occur if you have located any of your menu buttons wholly or partly outside of the safe TV viewing area. Go to your main project menu, then click on View/Show TV Safe Area, to check. Drag into the safe viewing area any buttons that are outside the safe viewing area.
Russ One - suggest this
Multiplex Error-There was an error during muxing preparation
One thing that worked for me was to export the video w/o chapter markers as a self contained movie (thereby not loosing the edits & etc). Then make a new FCE project and import that movie into a new sequence and add the chapter markers. I've used "-", "&" and "," with no problem in the chapter names. Removing the markers or exporting without them did solve the problem but renaming them with just numbers 1,2,3....5, did not solve the problem and since this problem seems to happen with with iMovie as well, it would suggest the problem is in the video or audio and in combination with the chapter markers iDVD just can't handle it. The only other possibility is that both iMovie and FCE share the same or similar chapter marker code that some how is corrupting the markers.
Summary - What to try
1. Chapters
Only A to Z and 0 to 9 in chapter title
No Chapter mark at very beginning of movie
No Chapter mark in or within 2 seconds from any transition in movie
2. TV-safe area for buttons (no one outside this)
3. Safe re-boot
4. No other external devices connected - that are not needed
SDMacuser adds to this
On #4 ... No ext. devices. Some think this applies mainly to ext. FW. Not the case. Also applies to ext. USB2 as well (not to mention flash drives too).
Do not leave 3rd party devices / camera / camcorder plugged in unless it is being used with iDvd's One Step process. Certain web cams can trigger this also (especially ones with added features like LED light/s that draw additional power from the FW or USB bus).
5. Minimum of 25Gb free space on Start-up hard disk
6. Make a DiskImage first - reduces where problem originates
7. Trash iDVD pref. file
8. Make a new iDVD project
9. Movies in project with same aspect ratio e.g. 4x3 or 16x9
10. No other programs/applications running during iDVD process. e.g. Internet, screen & energy savers
Max Mccarty
Mar 29, 2013 7:55 PM
I've made literally hundreds of DVD's using iDVD and I occasionally get the dreaded "Multiplex Error". In the past changing the position of chapter markers has worked, but sometimes the only way I can get the DVD to burn is to remove all the chapter markers (not a great solution).
Recently, I've discovered a bug in iDVD that creates the "Muliplex Error" message and it may be the cause of some of my previous problems. Sometimes when you export a movie to iDVD with chapters, it will create chapter menus with incredibly long playing times. My most recent "Multiplex Error" project had two chapter menus. I have a 38 second audio clip that I use for my DVD menus and the first menu showed the correct time of 38 seconds (select View>Show Inspector). The second menu with the same audio clip showed 13 minutes and 42 seconds! When I went to the Project Info window (select Project>Project Info) it now showed the total size of my DVD as 4.8 GB, too big for iDVD to encode. So, I manually adjusted the time of the second menu to 38 seconds. This time without changing anything else, iDVD burned the disk perfectly.
The interesting thing is that when I began the burn, the project info showed under 4GB for my disk. So, from now on I'll check the playing times of each menu before I burn.
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