Time code breaks.

Try this:

After fixing timecode breaks, export to MPEG and save it as one continuous file. Open that file in Streamclip and export it to QT. I don't know why you have timecode breaks from within one VOB file- you shouldn't as it is one contiguous MPEG-2 file.

How big a file are you working with? If you are working with multiple VOB's from DVD you don't want to be editing 4-5-6GB at a time anyway.

You might want to do one VOB to QT and edit 11 QT files. If you mean simple cut/trim editing to get small bits from the VOB's why don't you edit in Streamclip? It has in/out and cut and trim just like QT. Then convert smaller clips to QT.

If you are converting VOBs to QT the whole menu thing and such is long gone anyway - they depend on the proper DVD file structure and the IFO and BUP files so you have no ability to use them so there is no danger of losing them.

Size: 4.5GB to 72GB - sounds odd - you must have used a codec like Animation or DV to get that much and with DV it would have to be something like 5 1/2 hours of content.

If you want to just play the video just play the DVD. Really. What is the point of converting it to QT (and in your case a file 15 times bigger than you started) if all you want to do is watch it? You can rip it and open the VIDEO_TS file with the DVD player and watch that.

If you just want the main feature use Mac the Ripper and rip just the main title and skip everything else.

This is an unprotected DVD right? You can copy it with disk utility or Toast - make an disk image of it and then burn as many as you want.

Or rip it with MTR as you have done, buy Toast (essential disk product anyway), drag the whole VIDEO-TS folder into the program and make copy after copy.

I wouldn't convert DVD to DV and back to DVD unless absolutely necessary. This degrades quality.

Why don't you just make a copy of the DVD. This preserves the original quality.

Or, if you want to get rid of some footage on the DVD: Delete unwanted VOBs or clip unwanted footage with MPEG Streamclip and re-author the MPEGs with Toast, Sizzle, DVDSP etc.

OK, buy Toast. Spend the money it will be less frustrating. you can even download it and it is worth every penny.

Open Toast. Video Tab. Advanced options on the left. Select the choice make DVD from VIDEO_TS folder. Drag the folder into the big pane.

Go file make disk image. Name it, leave it on the desktop. Since the video is already rendered it will write a disk image in a jiffy.

When time to make copies: double click on the disk image or drag it to Toast - it will use the copy tab. Put in a blank DVD-R . Press the big red button. Wait. Repeat for other copies. You can verify the first one if you want, it takes a while. If it is OK, then skip it on the rest if you like unless you are watching the hockey game and then let it do its thing each time.

You can even mount the image after it loads in Toast by clicking the mount button and watch the copy of the DVD ,e.g. the image in the DVD player.

Quit thinking about converting all the time.

Toast will take iMovie project files directly into it and it will do any rendering to MPEG - you don't need to and QT would be the wrong format anyway. Plus you have no software to "reconvert back to VOB". QT won't make MPEG-2 nor do you want to constantly transcode.

Now all that said I am not sure the VIDEO_TS function will allow added media (e.g. a VIDEO_TS fodler then a bunch of random media).

If not you can make a second DVD with the Video tab, DVD Video function. Just add whatever clips you like, QT, iMovie etc., and Toast will convert to MPEG and make a DVD. There is even a media browser in Toast 7 to see all your clips in iMovie etc. Very slick.

I think you could then rip that DVD as well with MTR and put two VIDEO_TS folders on one DVD as long as there is room.

When you ripped the VIDEO_TS folder to the desktop, control-click on it and get info and see how big it is. It has to be bigger than 4.3GB to be a problem.

Toast 7.0.1 which you should be using will compress a DVD-9 (double layer) to fit a single layer DVD. I doubt it is a double layer original frankly, if it was not pressed in a DVD factory.

When you make the image on the desktop in Toast, how big is the image file?

You cannot split a DVD onto two DVD's as the menu system will go crazy looking for content. Use the compressing function built into Toast 7.

Rokaem
You mentioned that you didn't know what size the stuff was because you dumped the ripped image file, yet elsewhere say :

The "ripped" footage has 6 .VOB files totaling 4.59GB.

That sounds like an unlikely figure for a custom DVD-R (up to about 4.2Gig would be more likely)... just stick the DVDR in and get info on it for data/file sizes...

I suggest you look at dvdbackup, dvd2one and similar tools... which rip any DVD to an 'imageable' file, and squeeze 2DVDs worth of data onto one,
b respectively.
(dvd2one & similar will cost you quality - maybe too much with your material).

Toast is a great tool, but there are a lot of other ways to write DVDs

I would counsel that the best approach to your needs is mentioned above/earlier : simply dupe the DVD.

If you want to add /edit material you're getting into authoring - a much more complex area - particularly if you want to avoid transcoding/recoding etc... There are potential 'showstoppers': one example:- The commercial service might/probably have used tools not practically available to you - like hardware multipass variable bitrate (VBR) MPEG2 encoding (which usually gives smaller files and better quality). Most of the simpler faster tools (1 hr vs 30-90hrs) available to you are Constant BitRate (CBR) which normally gives much larger files.

In any event, you definitely want to avoid transcoding/re-encoding the original material - it's a very bad idea. (Simple 'assemble' edits, as suggested by other folks using a tool like mpegstreamclip to simply 'snip bits out' can be done to avoid most transcoding but you're still going to be confronted with an 'Authoring' task. Adding new material is unlikely to be straight forward for you).

My suggestion: simply dupe the DVD. (Fast, & There'll be no loss of quality at all).
If you have additional material, Author another.

Best wishes,