Hi atcain and welcome,
Personally, I haven't used Recode 2 for video archiving for a few years so I'm a bit rusty with it and no doubt I am running an old version, 18.104.22.168.
I used to use it along with dvd decrypter, etc., ... prior to Fab resolving its problems burning DL discs.
I'm trying to connect the dots as to how you took a Video_TS folder after being compressed with Recode 2 and simply burned it with Img.
Did you not also need to utilize Img Build Mode ?
This would have added an extremely small amount of data, but I suppose when factored in with your other steps, could have bumped you beyond "critical mass"...
Based on your statement,
"1) DVDFab (to rip ENTIRE DVD's)"
you're only ripping with Fab, not compressing...and then compressing wth Recode 2, right?
Did you tick on Fit to target in Recode 2?
Did you set the % of compression manually?
Anyway, I attempted to reproduce your problem.
I left Recode 2 on its default setting = DVD-5[4.7GB]
Here's what I got:
(btw, this is with Platinum 22.214.171.124)
Fab Rip:................7.05 GB (7,573,075,968 bytes) --->compressed with Nero--->
Nero Recode 2:....4.35 GB (4,675,436,544 bytes)
Img Build Mode:...4.35 GB (4,676,059,136 bytes)
Burned Disc:........4.35 GB (4,676,040,704 bytes)
The disc completed without issue and plays just fine.
I believe the vast majority of Platinum (& Gold) users use Img or VSO to burn. This is not to suggest that there aren't quite a few users that burn with nero or that there's anything wrong with nero.
DVDFab HD Decrypter will of course, have a ton of shrink users.
It's JMO, but I have never appreciated a benefit to burning with nero or shrink when comparing the quality of the final product.
For me, files processed and burned with Platinum, whether with Img or VSO are equal or better in quality to any burned with nero (including Advanced analysis and High quality mode) or shrink (including deep analysis).
And as already stated...
Using Platinum (or Gold) for the whole "enchilata" is quick and easy.