Problems With Dual Layers Break Points

I have 3 G5 Macs all without intell chip sets. I have tried this with all 3 Macs so lets take the newest one of the 3. Its running on mac osx version 10.4.11 Processer and is 4x2.5 ghz power pc g5 with hl-dt-st dvd-rw gwa-416sb. I can burn single DVD'S all day long, but the problem starts with dual layers. I am using verbatim DVD+R DL. I have one movie which is 2 hours and 36 minutes it burns fine when I burn a single layer, however when I try to build and format a dual layer I get that message window: formatting failed (its says formatting was not successful, the image exceeds the max allowed size for a dual layer configuration.) That is on automatic breakpoint. I have tried inputting in my own break point no matter where I put it the same message window appears. I am using DVD SP 4.1.2 also on FCP 5.1.4. I also tried buring dual layers on Sony DRX A10 UL-T all was working fine last year. I cant figure out why this has changed. Any suggestions will be helpful and appreciated. Sincerely Bob.

Welcome to the boards
Since you are using a Dual Layer Disc, there has to be a break point where it crosses over from Layer 0 to Layer 1, if you have no Chapter Markers at all (or a limited number of Markers, none of which fall near the point which is a bit more than half the size of the assets you will get an error that a Layer is the wrong size.
What you do is
1.) Set up markers in the areas where your would guesstimate the Layer Break(s) should be
2.) Build the project (but not format)
3.) Format a Disc (in the dialog that comes up, click on advanced tab, then where it says break point, use the pulldown which will have all valid breakpoint markers dark/black, while non-valid Layer Break Markers will be faded) If no marker is black there is no marker in the right place, regardless of you use automatic or not.
If the message is not for a layer issue as above (meaning one of the two layers exceeds the permissable size) then it can be an encoding rate issue. 2 Hours and 36 Minutes on a DL should be about 6.9 Average with AC3 audio @ 192. Even then it may be too close depending on menus and the rest. If using uncompressed audio or higher settings for video, could be the problem.
http://dvdstepbystep.com/faqs_7.php

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