Dual layer DVD playback problems

Hi Everyone -
I am struggling to make a dual layer DVD that plays back properly. It is for a 76 minute film plus several bonus items.
Total disc space used is 6.4 gig
The film was compressed to a bitrate of 7.1 with a max of 8.3
Audio compressed to 492 kbps (or whatever the 400ish setting is)
Project compiled fine (although I did get a "video bitrate too high" error the first time, then lowered the bitrate.)
Set to
red laser
dual layer
OTP
layer switch set for chapter 12
I've done a few test dual layer discs in the past successfully. What I have done differently with this one is add a lot of bonus material, so there are some 20 or so small video files and a commentary track and two additional audio tracks.
I do not get any error messages while compiling or burning.
The second attempt played back on my mac, at least the main film did. It struggled playing a couple of bonus features and would play others at all.
It loaded on my Mintek portable player, but wouldn't play any video.
It did not load at all on my Cyber Home DVD player or my Panasonic Blu Ray player.
I am wondering if all of these additional small files (none over 2:30 minutes) have caused some clutter that causes the machines to struggle.
I am also wondering if this will be solved by replication, which I am going to do.
I will keep trying though.
If anyone has any advice, please let me know.
Thank you,
Joe Grisaffi
Houston TX

You may want to lower your bitrates and audio rates. They seem high, and I am not sure how much the extra material is that you have (in running time), it looks like about 40 to 50 minutes, so total time of about 2 hours or so? The rate may just be too high for the player to handle. Depending on the material (fast action vs seaking engagement for instance) you should be able to get this on a DVD 5.
Make sure you also use DVD+R DL discs, they are the most compatible. I burn a ton of them and do not have issues playing them back. Use them all the time for proofing and testing prior to going to replication.
As to it not starting properly, some players can get a little finicky. A good practice is to start the DVD with 3 -5 seconds of black, usually in VTS 1 (when you look at the video layout). Also, do you have each clip on seperate tracks or one long track.
As to DLTs, replicators are now accepting USB files also with a "Tape Image" layout on them

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