Just wanted to say I’ve done more tests (and COW research) and I believe the problem was I was exporting at 2-pass VBR with a max of around 7, believing I was good to go.
I now learn that there is a ‘spiking’ issue, wherein the bitrate will go up above the max, sometimes one or two mbps. I’m quite sure the spiking was causing my dvd freezing or stuttering problem, and the inconsistency as well– since some discs were handled and others were not, by my dvd player, and perhaps depending on the 2 pass vbr, different areas of the film were encoded differently with different bit rates each time (?) Not sure about that.
(Anyway, this spiking problem seems to be something that should appear right in the help manuals and basic literature, not something I should have to research and dig around and waste 50 dvd’s on, since it’s easy for somebody to mistakenly set a max of 7 or even 8, thinking they’re safe.
Anyway I guess this is just more doing and learning from experience and– reading experienced pro’s opinions. I just hope this didn’t cost me numerous festival entries because the discs I thought were good were freezing an hour in…)