Problems Formatting/Burning

I burnt a few test copies of my DVD project successfully.
But then had to make some changes.
I recompressed my files and it all played fine in the simulator, but now when I try to burn a copy it gets right across to 95% and then I get the following log:
Starting DVD Build LFF...
Compiler Initializing...
Precompiling Project LFF
Compiling VMG Information...
Created 10 PGCs in VTSM1
Created 8 PGCs in VMG.
4 Menu(s) will be created...
Compiling Menu PGCs...
Compiling Menu#1 (Tutorials)...
Compiling Menu#2 (Billy Movies)...
Compiling Menu#3 (Extras)...
Compiling Menu#4 (Main Menu)...
Writing VIDEO_TS.VOB
1 VTSs and 4 Titles will be created...
Compiling VTS#1 (Track 1)...
Muxing VTS011.VOB
Video File Read Error
Build cancelled
Building was not successful. See log.
My DVD data size is 4.1GB.
Can anyone help??
Thanks in advance

I've just reopened FCP and seen a file (one of the menu backgrounds) that wasn't rendered - although I am positive it was rendered and it played fine in the DVDSP simulator.
What didn't play fine in the simulator when I've just checked back is one chapter of the track where the audio plays but the video freezes. I am re-rendering this clip in FCP now so will see if that is the problem.
I am running the whole project from an external drive via USB.
I run all the files through Compressor and create M2V and Dolby Digital Audio files for them all.
Thanks.

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