The facts are Apple released an application that is supposed to work without problems within their OS.
... and how long have you been working with computers? Unfortunately, EVERY computer is slightly different and it's impossible to test software on every possible variation. If you have a solution to this issue, I'm sure you can make big bucks in the software industry.
We have seen a case or two in the past that appear to be cases where iDVD THINKS the raw content will mpg-2 compress enough to fit on a single layer disc, but the compressed content ends up a litle too large. It's ALWAYS a good idea to make your iDVD 'burn' to a disk image file. You can then verify that the DVD does exactly what you want. Then you can burn the image file to an actual DVD disc with Apple's Disk Utility or Roxio's Toast Titanium. Use good quality media (Maxell of Verbatim) and burn at 4x or lower if you want your discs to be compatably with a variety of set top players.
Have you tried creating a short test disk image file out of iDVD '08 to see if you have a real iDVD '08 problem or content problem?
If you can, please try to keep you replys short and to the point - excess 'verbage' only serves to make your postings difficult to get through.
What I have read throughout posted forums and discussions are lots of upset-lost users encountering problems with their upgraded iLife.
The nature of the forums is that you see problems - that is the very reason they exist. None of us trying to help people solve their problems here are employed by or represent Apple. We are all simply other users trying to help based on our own personal experience. None of us are mind readers so the better the information we get in a posting, the more likely it is we can help. Flames and rants tend to 'turn us off' and make it less likely we will even try to help.