Encore 4.71 gb problem

Hi new to the forums so forgive my newbness,
Here is my issue I have been using Encore for a full year to author Bluerays with Precompsed templates. Then when I am done with the blueray .iso file I go back into Encore and change all the settings to make a DVD. It has worked fine until now.
-One project is crashing on me evertime I do a DVD author with no error messages.
-The other (Which is the smallest project I have done this with) will only burn the file out at 4.71gb which is .01 over the DVD limit.
DVD duel layer is not a solution as my clients will not be able to play them. I run a wedding business and the end product must be both DVD and Blue Ray.
I am running Encore 4.0.0.28
On a Mac pro with more then enough power to handle any compression i throw at it.
An Ideas?

>when I am done with the blueray .iso file I go back into Encore and change all the settings to make a DVD
I don't do BluRay, only DVD, but as far as I know the "best" way to be sure Encore will make a DVD where everything fits is to feed Encore DV AVI files (for you, some kind of Standard Definition MOV file, I think) and then let Encore do automatic encoding to do the calculation to balance the size of the DVD to the size of the video
I know that you can create MPEG DVD files out of Premiere Pro, I simply choose to let Encore do all of the calculations for me
I go from AVCHD to DV AVI in Premiere Pro http://forums.adobe.com/thread/652694 and have never had a problem with my video fitting on a DVD

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Thanks for responding.
Truth be told, I got so focused on the Encore problem, it didn't occur to me to see whether Media Encoder was still functioning properly on my machine.
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Thanks for taking the time to help me out. I just purchased my non-linear with CS4 Production Suite and the Matrox RTX2. I have several projects that I am working on right now and I was advised by Adobe, Matrox, and my non-linear vendor, 1 Beyond, to finish those projects before performing updates.
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I wanted to just plug it to my pc via a usb ... I have no idea why the usb doesn't work ... not connecting,
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Guten Morgen,
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Hi there
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http://www.adobeforums.com/cgi-bin/webx?128@@.3bbf5520

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