MPEG 2 failure on compressor export

I Have recently changed from using  single layer DVD to dual layer DVD and I've got some great results Using the send to compressor route and changing bit rates to suit.
however after about 4 successful projects burnt to DVD I'm now getting failures on all the mpeg2 ( video ) during the compression process from FCP 7 to comp 3.
the AC 3 audio comes out fine but every time the. Video is now failing and I can't see why.
MY route is this:
1. Export using send to compressor in FCP 7.
2. In compressor I select preset apple DVD 150 mins all
3. I then select video file and change max & min bit rates to 7.2 & 5.5.
4. Submit.
audio takes about 25 mins to complete and video fails every time.
cant work out where I'm going wrong as the first 4 projects were fine, now nothing !
dont want to go back to 4.7 GB's discs as the quality is so much better with dual layer.
can anyone help with this strange problem?
these are wedding DVDs and are both 2 hr 30 mins long roughly
thanks in advance

In order to troubleshoot, first, fully render your sequence in fcp, then export a selfcontained quicktime with current settings from frcp (file:  export:  quicktime movie NOT quicktime conversion) and bring that file into compressor.  This will hopefully help isolate the source of the problem.
The other advantage of using this workflow is that you can enable qmaster to greatly speed up the processing time in compressor
http://www.digitalrebellion.com/blog/posts/using_compressor_with_multiple_cores. html

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