Unfortunately the disc has a mutli level menu structure.

I imported the DVD into Vegas just to see what it would look like. The media that needs to be replaced came in as VTS_01_1(01).mpg

Could it possibly be as simple as:
- creating the new content
- rendering it as VTS_01_1(01).mpg
- burning everything to a new DVD with ??? (maybe Nero)

You're close. But that wouldn't quite work. The Vegas import strips out the DVD-related header and converts the file to a regular MPEG. If you put a regular MPEG back into the file structure, your DVD player won't know what to do with it.

I've done the following with movies in a DVD projects, so it should work with an intro:

1. Copy the original DVD to your harddrive using Windows Explorer or Nero (guessing it has some kind of Copy Disc to Drive function somewhere). Don't use the Vegas import tool for reasons stated above.

2. Play those files in a DVD player app in order to find the file that contains your intro. I'm guessing it will be VTS_01_1.VOB. Make note of that name.

3. Create a dummy project in DVD Architect and add your new intro media. The project should be menu based, but it does not need the same structure as your original DVD.

4. Prepare this to a folder. When that's done, play the files there in order to find the intro media. It's probably VTS_01_1.VOB here as well.

5. Copy the new intro VOB over the old one, and burn that structure to a disc. You can do this in Nero or just in DVD Architect (pretty sure the option to burn a previously prepared project was available in DVDA3).

Rob

Thanks for your clear directions. I'm close.
The new introductory media starts fine BUT the end action goes to the wrong clip.
How do I troubleshoot that ??