'Project exceeds disc capacity" but it shouldn't

What source CoDec do your files have? Perhaps it's just a timecode problem and
Encore does a wrong estimate based on that... Also: have you ever tried creating
a custom transcode preset? I usually find the default ones not well enough
balanced and they are prone to causing errors. What problems do you experience
in teh other programs?

I just use the basic Premiere AVI codec, capturing everything as a standard DV
AVI, then exporting it with all the same settings and then importing that AVI
into Encore. The problem is really random. Sometimes it only makes it a 100mb
too big for a DVD, sometimes it's 4 or 5 gb's too big, other times it's perfect.
I've been using Adobe stuff for years and years and have never really had
problems until CS3. Here's my problems:

Premiere:
-if I disable audio (hiding it) Premiere pops up an error when trying to play or
scrub the timeline
-chapter markers created in Premiere will not show up in Encore if the project
is too long (like around 1 1/2 hours)
-random crashes for no reason
-gradient wipe has a glitch where it doesnt really complete the wipe. it's like
the wipe is only programmed to do 90% of it
-when importing WAV's I sometimes have to choose "all files" to find
it

Encore:
-crashes sometimes when saving a file in Photoshop and going back into encore
-projects exceed disc capacity for no reason

Photoshop:
-corrupts files. i'll save and close a file, then reopen it and it says its not
compatible