Dvd freezing

I have a fairly complex iMovie project. 1hour 29 minutes. I have shared to iDVD and made a disc image. In spite of doing this twice the resulting image when burned to a dvd freezes at the same point every time in both a pc and two dvd players. The original iMovie seems to have nothing special at that point - not even a clip join and no added sound.
Tried using Toast 7 ( very new to it) to do the same and the resulting disc image has menus, good sound (both from the original camcorder and the overlaid commentary) but NO VIDEO PICTURE at all!! A black screen in mac dvd player and same if I burn a dvd and try a dvd player. The disc image "xxxx.toast" file seems quite small - 1.39GB I know this is an Apple discussion but.. (and Roxio's discussions do not seem to be working!)
Any thoughts how to get out of these problems?

I have removed all my chapter markers and am currently creating a disc image via Toast.
It sounds like you're using Toast incorrectly... Toast should be used to burn the disk image that iDVD creates, not an image create by Toast.
I use Toast 7.0.2 a lot and have ZERO trouble, including iMovie 6.0.2 projects with chapter markers sent to iDVD.
How to create a disk image from iDVD:
File/Save As Disc Image...
http://docs.info.apple.com/article.html?artnum=164927
This will isolate any encoding/burning issues you may encounter. Once the disc image is created, double-click the .img and burn the virtual disc that should appear on your desktop, using Toast to burn the DVD. Disk Utility to burn the .img file. Usually, you can select a burning speed in Disk Utility.
There are variations to this process based on which OS X you are using...
Open Disk Utility (in Utilities folder in Applications folder), click on the virtual disc (maybe the .img) in the left-hand window. Click the Burn icon. A new window should drop down and your SuperDrive tray will open after clicking the Burn icon. Insert a recordable DVD. (Verbatim DVD-R preferred by me.) Click the Close button. Wait. Select a burn speed. If you hold your mouse cursor over the pop-up it says: "Select a slower speed to work around burn failures," so select 4x or slower for best results. Then click the Burn button.
-->If the virtual disk selection won't allow you to click the Burn icon, use the .img file instead. This may have changed in 10.3.9 and did change in Tiger.
Also, you can use DVD Player to play the virtual disk to check your iDVD project before burning to DVD. Launch DVD Player. File/Open VIDEO_TS (Open DVD Media... in Player 4.6). Find the VIDEO_TS folder and open that. (The audio folder is for DVD-Audio disks.)
http://docs.info.apple.com/article.html?artnum=93006

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