IDVD can't create disc image

I posted this in the iDVD forum and it was suggested that I also post it here, since its an FCP movie.
(I use Final Cut Studio 5) Here is my iDVD post:
(I have searched iDVD for solutions and have tried all i could find, as you'll read below, but still nothing worked for me, .....)
I made 3 movies in Final Cut, exported them as stand alone movies. (This is the way I have done it in the past)... one is 43 minutes 16:9, one is 43 minutes letterboxed, other is 9 minutes 4:3. They had chapter markers in them.
Created an iDVD project, widescreen format. Added the movies ( both by dragging and dropping and by 'add movie' command) and created a slideshow, with added audio.
I 'Save as disc image' so i can burn several copies. This I have done a lot of times, in the past.
Since Friday last, every attempt has given me an error: Multiplexor Error ...There was an error during muxing preparation (Project conversion) is the most common one. (I don't know how to access Terminal for more details)
I have tried:
• I first encoded at Professional setting .... error message
• changed the encoding to High (to fit all three movies) ... read here that the Multiplexor error was due to the app not calculating the size right ... same error
• removed the plist ... same
• moved files off my hard drive for more space ... same result
• removed the letterboxed movie to decrease size: same error
• chapters: idvd did not recognize the FCP chapters (never had this problem before) so added ones in iDVD ... same error
• removed idvd chapters... same result
• went back to FCP and removed the chapters and re-exported the movies .. same result
• change encoding to Best Performance (only 2 movies and slideshow now) ... same result
• changed the theme ... same
• removed the theme's audio... same result
• reinstalled idvd ... same
• brought the movies into iMovie, added chapters and exported (as QT movie to DV stream) ... same error, and the chapters disappeared again
• saved the dvdproject in the Documents folder on my hard drive (thought this would do the trick as it had been on an external) ... same error
I don't know what's left to try!!
I'm doing all the things that I used to do but am having no positive results . The only thing that I have changed since the last dvd I made (a year ago) is upgrade to Leopard and Snow Leopard.
Can anyone help me ... please? This is a commemorative project that is needed for an association's archive, so I can't not do it. I'm just at my wit's end and don't know what other measures to take. (other than use DVD Studio, and don't know how!)
Thank you
Elizabeth
Added FCP info:
movies were exported using QT conversion
Format: QT Movie, default settings
Options: size: NTSC 720x480 4:3 (for small movie)
Settings: Best; Keyframes Automatic; H.264, 29.97 fps; no internet streaming.
For 16:9 movie: same, but Size: Current (630x354)

.... so when you all were telling me to use Compressor and DVD Pro, I went to the local McNally-Robinson and checked out the resources there.
Found a Mac Genius book on FCP, which lightly touches on compressor, and an Apple Pro training book on DVD Pro 4, which also touches a bit on Compressor but gives specific instructions on settings to get me started (and which i have since experimented with).
So I naturally bought them and have been reading in steps and then going to work. (That's why i haven't replied to you: wanted to be able to give you a report.)
Since last week I have
• compressed 2 movies, and recompressed the main one several times to fine tune the quality
• made a dvd pro project (and 'saved as' in various versions and configurations) that has:
• a 16:9 video with chapters, added in dvd pro
• a 4:3 video with chapters( Dvd pro) converted to individual stories
• a slideshow
• a folder added to the dvd-rom with the photos used in the slideshow
• an intro menu with my own livetype generated background movie (also used in the video)
• the dvd template used changed to 16:9 instead of 4:3 aspect
• 3 chapter menus for the 16:9 movie
• a story menu for the 4:3
• background music, different for different menus
• remote control connections, for the tracks and the menu (that all work) (except for one problem that I have posted in the DVD forum)
• built and formatted a few of the configurations to make disc images that then played in dvd player (but haven't burnt to disc yet as i am waiting to solve the final 'menu' button problem)
Haven't done scripts or layered menus, or subtitles yet, and none of my work uses alternate angles, but i think I've got a fairly good handle on this now. And I think I'll use DVD Pro and Compressor from now on .... they're great and DVD pro is much more able to be individualized.
I still need to experiment more with Compressor, tho', and to learn more about the compression codecs.
(I don't like the quality of the Livetype segments in the 'send to QT' option form FCP, they're blurry. And the 'using Compressor' videos have nice crisp text, but there are residual lines in the edges of things wherever there is movement. I always set the Motion Estimation as 'best', and 2 pass VBR Best, and in the last one I tried, i set the Average bit rate at 7.6, max 8.9 and the GOP to IBP, size 7.
Doesn't seem any different from the others, just a teeny bit larger in size. But i'm happy with it for now, no more time to tinker with this part on this project.)
So thank you all for your help, and i will now start posting any problems with this (or any other) project to the other forums. (but I'll check back here again in case you have another bit of advice for me
Elizabeth

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Hi,
I've started experiencing this issue with version
6.0.3. When I save my iDVD project as a Disc Image
and play it on my computer, there is no audio
(volume) when the video plays. First time, I didn't
bother to test the disc image and burnt it to a DVD
and found that there was no audio when I played it
with my DVD player. But then when I directly tested
the disc image, there was no audio in it either.
I went through a few posts on this discussion forum.
One of them suggested using an earlier theme from
5.0. I tried that too with the same result. For some
reason, there is no audio in the disc image. When I
play the footage directly in iDVD, it plays fine with
full audio, so I don't think there is any issue with
the way it was exported from iMovie to iDVD.
I've used the same DV video camera before to import
to iMovies and and then export to iDVD. I've never
had this problem before. Anyone else facing this
issue?
Also, I have tried exporting to Quicktime directly
from iMovie and I get a pop up saying some unknown
error was encountered.
Please help!
I've had the same problem (as have many others), and I've found both an odd related symptom and a weird fix, not mentioned in any of the posts I've seen. I also use iDVD6.0.3.
First, the odd symptom: after you build the non-working disk image, check the VIDEO_TS files that it produced. In my case, they all had a date-time stamp about 36 hours into the future. From a programmer's viewpoint, this looks suspiciously like a memory leak (i.e. data overflowing its allocated bounds and corrupting some program instructions or other critical data).
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