Some production notes on making a DVD-9

I've had more problems than usual in making one of my usual DVD-9 projects and thought I'd document them (and my solutions/workarounds) in case they come in handy for someone else.
* I usually do a DVD-9 of four videos, each of which are approximately 58 min 30 sec long (plus or minus 10 seconds). Each video has about 40 chapter stops. The DVDs also usually contain many many many menus, including a few motion menus.
* This time we're trying to do a quickie DVD-9. The four videos have significantly different runtimes (more on that below), there are only 6-8 chapter stops per video, and I only have 6 menus (none of which are motion menus).
* I captured all videos as uncompressed SD via an Aurora Pipe Pro and compressed with Compressor 2 (due to a variety of reasons), average bitrate of 4.4Mbps, max of 7.5, 2 pass VBR best, with best motion estimation. Of course encoding audio to AC3.
* First problem: tried to build/format a test to a double-layer DVD+R, and I got the dreaded "couldn't find a valid break point" message.
Note that NORMALLY I never see this message, as I have a lot of menus (including motion) and four videos of almost the same size. Therefore, Layer 0 gets the menus + 2 videos, Layer 1 gets the other two videos, Layer 0 > Layer 1, DVDSP does not have to place a break point within a video, everyone's happy.
This time, with the videos being different sizes and not a lot of menu space, I had to shuffle their order around in order to get Layer 0 > Layer 1 and not require a break point in video. (Since I'm in DVDSP4, I did it in the VTS view of the Outline palette)
* Once I burned the DL DVD+R, I tried to play it on an older Samsung player. It refused to play the first video on Layer 1, and hung at a couple of high-bitrate areas. A newer Panasonic player worked just fine. Moral: DL compatibility is spotty: don't be surprised if things don't work.
* I then noticed that one of the few high-motion sections of some of my videos (camera motion on top of crossfades) were encoding horribly. Lots of picture breakup (macroblocking). I re-encoded out of FCP4 after placing compression markers liberally at the beginning of the fades. No difference.
The fix (which I think I recall hearing about here) was to change Motion Estimation from Best to Better. I encoded just the 3 minutes of the video that contains this section, and it encoded without macroblocking. The test will be if re-encoding the entire hour of video with Better motion estimation still allows that section to appear properly. If not, I'll encode each hour into three parts: stuff before the high motion, high motion (with whatever settings work), stuff after the high motion. Then I'll append them in DVDSP or MPEG Append.
Anyhow, hope that helps.

Did you get a chance to try the encoding in BitVice (or anything else) to test whether it is a Compressor issue or a precision issue?
Yes, that fell under my "due to a variety of reasons" category. Turns out that, since I upgraded to the latest FCP Studio, I can no longer export movies that use the Aurora 10-bit Uncompressed codec that the Pipe uses to capture. The second I try FCP crashes. So I can't export it to use it with BitVice. Actually, I could use Compressor to transcode to Apple's 10-bit uncompressed, then use that in BitVice, so maybe I'll try that.

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5.0Mbps -   95 minutes
6.0Mbps -   82 minutes
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