You can use DVD Decrypter or SmartRipper to actually "demux" the audio file from DVD 2 and the Video stream from DVD 1. Use IFO mode, with Stream Processing turned on and tick the English adio track only and wjhile highlighted, tick the Demux box. Then run and you will end up with a large AC3 English audio track. Its synced to a NTSC 23.976 fps video,so you need to use BeSweet to convet to an AC3 that can sync to the PAL (25 fps) DVD1's video stream. As you said, you will need to chop or extend in places the audio track to "fit" to the Video. I would then author the Video & Audio track in Maestro, DVDLab or TMPGenc DVD Author. If its greather than 4.37gig, you can use Shrink or DVD2ONe or similar to bring it down in size. If less than 4.37, just burn out with Nero/RNM/etc.