IDVD and Toast-anyone else had this problem?

I apologize for the long post, but it is necessary to explain the situation.
I have made 4 projects in iDVD6, 2 SL, 2 DL with no problems. I edit in imovie, send to idvd, then make images which I burn with toast (though I know it is not recommended for the DL). I have not had a single problem....until 2 days ago.
I have created a 5th project, a DL, in the exact same way. The problem this time is that when I try to burn it with toast, I get this error:
Sense code = illegal request
Sense key = 0x26
Invalid field in parameter list
The toast people have been no help. They say it's just a problem with the image file. I have re-encoded it 4 different times (14 hours a pop!), to no avail. I was able to burn one of them with disk utility, but it no longer will . The image mounts and plays just fine on my mac.
So....I tried burning straight from iDVD. I get the "multiplexing" barber pole for awhile, then it says "finished recording", spits out the disk (still blank) and just freezes. I have to force quit.
I have tried trashing preferences, repairing permissions, all the suggestions I have seen in these forums and nothing is helping.
Thanks for bearing with me through that explanation. Is there anyone who can offer any suggestions? I would be forever grateful!
Emac G4 Mac OS X (10.4.5) LaCie external dual layer

Yes, my chapters follow those rules. The image file is 7.6 GB and I have 30 GB free on my startup disk. If it matters, I always encode onto and burn from an external hard drive. I am starting to wonder if my drive is the culprit. I went back and tried to re-burn old images that previously burned fine and am getting the error with those, too. I am going to try to get some input from the LaCie folks, too.
If anyone has anymore suggestions, I would be grateful.
Emac G4 Mac OS X (10.4.5)

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