I checked the size of my still and they are all under 500k.
I am using Premier Pro 1.5.
I was doing some reading last night and found that if your DVD is less than 90 minutes long, the encoding should be at NTSC 4×3 high quality 7mb VBR 2 pass Surcode for Dolby Digital 5.1.
(if all else fails read the manual!!!!) Should have looked there first.
I don’t know if this will make a difference but I’m going to try that.