Geez, this stuff just keeps coming back to haunt us, doesn't it? I have a similar issue with my older pc. I've tried darn near everything, flashing drives foward and backward, uninstalls, reinstalls, reg cleaners, etc., etc., ad nauseum. My newer custom pc remains unaffected.
Anyway, I've noticed that this is related...only to fab and only to -R media...at least, for me. We saw this -R issue last year and it plagued us for several months and was finally fixed ...I believe by portmac and vso.
Recommend that you try a +rw disc and I'll bet you will not reproduce the failed error. I just picked up some + TYs (Yuden 000 T02) and they work like a charm, in both systems. So, option #1, use +R media until this is resolved (this assumes a successful burn with +rw).
Option #2, burn with nero recode2, it takes some time for the burn, but it'll work just fine. You don't need to do anything fancy. Rip with express, but choose a folder as your target, not your burner. Close down fab. Open recode2, choose "Recode an Entire dvd to dvd" (assuming you want to burn the entire file you just ripped,you can modify what you ripped if you want). Click on import and simply choose the folder you just created. Click next, and disable "burn at once", and be certain to enable "advanced analysis" and "high quality mode". Also choose "high" priority under "more". You should be all set. Post back if you have problems...I've heard nero 7 can be a little buggy.
Hope this helps,