Ok, I take movie A, rip it with Smartripper, produces m2v & ac3 files. Open a new project in Spruce, import the m2v file which then imports the ac3 automatically. Then goto export to a disk image. The target drive shows the VIDEO_TS and AUDIO_TS folder in which it creates the vob's and ifo's etc. I also have the disk image target set to the same drive/folder, this produces and movieA.img file, I then open this with Prassi PrimoDVD and burn the image. Take movie B, do the exact same things, works perfectly again.

Take movie C, follow the same steps, but use ReMPEG to downsize the file (to 4GB). When the process has finished, again Spruce produces the audio & video folders with the vob & ifo files, but the .img file remains at 0KB i.e. it doesn't produce an image. The end dialogue box say "Image Created Succesfully", but the top of the dialogue in the blue bar says "Error".

The only difference between movie C and movie A & B is the movie A & B are PAL, whereas movie C is NTSC. Movie A & B are 1Hr30 mins and 1Hr15mins, movie C is 2Hr7mins hence the need to downsize/resample. I HAVE set the preferences to the respective television standard in Spruce File -> Preferences.

When I open PrimoDVD, I can drag the audio & video folders to appropriate place and burn the movie (C) without a problem, and it plays fine.

I thought that as movie C is longer (larger file) that might be the problem with FAT32, so I converted to NTFS to see if that will cure the problem. Didn't make any difference. Anybody have any ideas on this?