[Chris Oben] “if I had the time to play I would welcome the opportunity but my client needs this DVD quickly. Do you think it would be easier in DVD Studio?”
Well you already have the m2v and ac3 file so DVD SP will be MUCH faster, those two files are already to be brought into DVD SP, because they are already encoded you will not have to wait for the long encoding process in iDVD, nor will you have to wait for then to be muxed together before you let iDVD encode then all over again. The work flow you are going with is like taking 2 steps forward and then 3 steps back.
Check out this tutorial about making a simple DVD menu in DVD SP, or you can also use a template.
https://www.pixelcorps.tv/macbreak93
With DVD SP you could be done in a fraction of the time because you already have the pre-encoded m2v and ac3 files that are needed to make the DVD.