What I've tried has been taking out enough of the main title vob's to get all the menu's, extra's, etc to fit on the first DVD and putting the rest of the main title on a second (yes the second won't be playable.)
Nero generates a "DVD Video files reallocation failed" error message. Continuing on results in one of the .VOB's VTS_02_1.VOB in one case or 041 in another test to be slightly modified. And the trailers and stuff didn't play from the menu's anymore.
ImgTool classic always generates an 8 gig ISO even when only there are only 4 gig of files present.
I could do just a straight file burn (not video) in Nero but I would like the menu's and extra's to be playable if possible. Another requirement is that I be able to recreate the original dl dvd in case it becomes damaged. So, something like DVDFab which mucks up the menu's wouldn't work.
Any thoughts on how to accomplish this? Sorry for the long post.