DVDs never burn!

Hey all,
I have been having this problem for weeks now, where I go to burn a DVD, leave, come back the next day and it still shows as "multiplexing and burning". I hit cancel to no avail...I end up having to force quit...and even though iDVD says it was burning, the DVD is still blank after all this (so no burning took place).
I have already made several DVDs doing the exact same procedure, and in the past, never had this problem (they usually burn in about 45min). All of my iDVD projects are created from iMovie, but even when I create an idvd project from scratch and import the movie I still get the same result. I tried switching between "best performance" and "best quality"...again no result.
I'm running version 4.0.1 with iMovie 4.0.1.
If I can't get it to work, would it be worth it to upgrade to the latest version?
Anybody else run into this? I'm backed up with work now because of this, so if anyone has any advice it is greatly appreciated!
2 ghz G5 Mac OS X (10.3.9)

...one had about 7GB free on the start-up drive...
that is definately not enough to let iDVD do its job (even MacOsX shoudl have more space on drive…); with so little space, your app will crash/freeze…
...These folders are sometimes on the start-up drive, sometimes on a secondary internal drive....
my, allways successfully workflow:
* editing in iM, project is on external drive…
* project finished; transferring project onto internal drive, "Movies"
* launch iDVD, choose project, burn…
problem with files stored here&there: iDVD (and iM) needs to "collect" all files…- that has to be done "on time", means, if e.g. an ext. drive falls to sleep-mode, that millisecond of getting it awake can make iDVD freeze... secondary: ext. drives need to beo formatted correctly for use with video! (MacOsX Extended…); any usb2 connection could work, but isn't as reliable as firewire…
you did export from within iM as "QT Full Quality"? or how…?
my line "iDVD expect a Movie folder" just means, some clever ones "clean-up" their drives and erase this folder… No Movies on start-up drive => no work of iDVD… you don't have to store your projects there, but, my experience, it does work this way…
you did try to create an image in iDVD and burn that later with Toast (sorry, got lost in this thread, too many thread-jackers here.....)?

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Jordy, welcome to the forum.
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DVDs never burn!

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