Here's the setup:

Demuxed a movie (with VOBEdit) to an M2V, AC3 and SUP.
Used VSRip to get a SUB and IDX.
Used Subresync to create a new SUB/IDX with only subs to be "forced".
Used SUB2SUP to create a new SUP file from new SUB/IDX.
Used IFOEdit to extract chapter (cell) times from original PGC.
Tried to author DVD from M2V, AC3 & two SUPs using IFOEdit; worked, but chapters are way off.
Used Rejig to demux this new DVD and extract "ChapTimes.txt" from original.
Tried to DVD Author from Rejig using M2V, AC3, two SUPs & ChapTimes.
Status bar reads "Multiplexing..." while Mux.vob builds. (Builds to slightly over 4Gb which should be fine as drive is NTFS.)
Status Bar changes to "Create DVD Structure...", Mux.vob disappears and process ends (Status and Progress bars clear and "Stop" & "Create" buttons shift focus).
VIDEO_TS folder contains only 1 VOB, which is 12k in size. IFO sez VOB is ONE FRAME(!):

Tried a few other experiments: no subs, no chapters, neither... same result.

I have only seen a couple of other postings indicating people seeing this same thing with Rejig's DVD Author, but no one replied to them. Anyone with any insights into this? I'm stumped...

Thanks!