This may be of some help to previous posters on this subject but I also have a question so I posted it as a new topic. I have successfully copied several DVD's up to 2 hours onto one CDR. I followed this guide at http://www.afterdawn.com/articles/archive/dvd2vcd_with_smart_dvd2avi_tmpgenc.cfm . In TMPGEnc, set the rate control mode to Constant Quality with quality at 50 to 70. Set the audio bitrate to 128. This gives decent quality but I'd say it's about equal to a VHS copy. The longer the movie, the lower the quality setting has to be to make it fit. Be sure to start a new project before you begin or it doesn't seem to work right.

As for my question, how many DVD players will play this type of movie? I believe it falls into the XVCD category but uses VBR in VCD mode, which isn't a standard. My Pioneer DV-250 plays all of them but I'm worried that my next player won't. If someone else has tried this, I'd like to hear from you.