After some hunting around I couldn’t find a solution, I started realising could be a layer break causing the problem. Encores layer break setting is a mystery at best, and an inconfigurable monster at worst.
Until I looked into a program called Ifoedit, which brokedown the IFO files and within that listings of any Layer breaks – which was within a minute or so of the glitch. So I’ve rerendered the M2V at a slightly lower Bitrate knocking off 200mb of size and WaLa – working disc!
So there you go – if you’re having a problem with Encore on what seems to be a good project in this area then this could be the problem.
Of course once I got the OK from the client it soon became apparent that no one at Adobe ever sent a Dual Layer master off for duplication. The duplication company asked for the layers to made seperate and supplied on 2x DVD-R’s – something Encore doesn’t do – infact unless you’ve got a DLT you can’t do it. Pretty annoying to have such a feature missing – luckily Gear Pro allows ripping of a disc back to 2 seperate DDT files to supply – I hope Adobe adds this feature ASAP – small production facilities have no need for a DLT the rest of the time and supplying work as an IMG/ISO file is a pretty obvious delivery process.