I was putting the finishing touches on a particularly long DVD the other night. I added a video to the opening menu that clocked in at just over 16 seconds. I then added a 16 second AC3 and Prepared the disk. I was told that the Main Menu was oversized. Looking at the Optimize screen, I saw that the Main Menu was *6 GIG!* So I checked the sources and all looked well. After MUCH experimentation, I found that it was the AC3 that was freeking the setup out. I removed it and the menu went down to 17 meg (about right). I re-encoded the AC3 and it was about 400k. Plopped it back into the menu and had the same problem. Encoded that audio as a WAV (about 2 meg) and all is well. DVDA will have to re-encode the WAV, but it fit nicely.
Why would an AC3 do that? -mjr