Idvd wont create a disk image

I am using imovie '09 v. 8.0.6 and idvd v 7.04 which came with ilife '09
As I am still using a PowerPC my future upgrade is limited until I move upgrade intel cpu.
I am trying (without success) to burn a 40 min movie to idvd. The project also includes a 67 photo slideshow, all pictures are around 18mp jpegs.  I have 42gb of free disc space before I commence the burn and on the last two attempts, I have had the following problems.
1. idvd wont complete encoding when using Revolution theme.  Also, Revolution chapter theme (second screen) will not play audio depsite the inspector showing the audio is enable in the audio drop zone.  On my last attempt, on exporting from imovie into idvd, no audio soundtrack in idvd despite the project worked fine within imovie. 
2. I feel Revolution theme has a bug whereby audio won't play on the chapter page despite it being enabled in the audio inspector window.
I have deleted my com.apple.idvd.plist file as suggest in other threads (as I understood idvd would then create a new one) but the problem prevails.
I have also repaired all my disk permission through disk utility as also suggested.
Can I reinstall just idvd from my ilife disk and would this affect the integrity of any existing projects? Alternatively has anyone any suggestions on how I may finish the burn to a disk image. 
PS All worked well on my last project a few weeks ago.... I have a hunch it's the file size.  All suggestions welcome.
Many thanks in advance.

Thanks for responding Bengt.  Here is the workaround.
Problem:
imovie '09 (8.0.6) looses all soundtrack when sharing to idvdv 7.0.4 plus idvd wouldn't allow creation of a disk image.
Findings:
It would appear all my problems start with the fact my machine - PowerMac G5 1.8ghz dual proc. 4 GB RAM IS NOT sufficient to run imovie '09.  Depsite the fact I was able to produce my project in imovie, the problems began as soon as I started to share and burn the project with idvd.
See confirmation of this point from Appleman on this thread:
https://discussions.apple.com/message/15443520#15443520
Solution:
1. I copied the imovie project to an external drive connected to my PowerMac G5 via FW800.
Note it is vital you follow this process to copy an imovie project from one drive to another:
http://docs.info.apple.com/article.html?path=iMovie/8.0/en/19548.html
This process ensures all links are preserved.  This worked perfectly for me and I understand it is the correct way to move imovie 09 projects to other drives.
2.  I then disconnected the external Firewire drive connected to my PowerMac and connected it to my MacBook (Intel) to the Firewire drive using FW 400 to 800 cable.  After ensuring the drive could be viewed in finder by using the drives mount software, I then loaded imovie '09 on the MacBook.
and the drive then appeared in the imovie project window.
3. Share project to idvd, complete project in idvd by adding a slideshow.
4. Created a disk image in idvd - Note - I saved the idvd project and the disk image back to the external firewire drive given I had 1tb free space.
The problems were (imo) all caused by using an old platform PM G5 non Intel and lack of internal disk space.
Thanks Bengt and Appleman for all your help.

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