Burn2.9 converts video file OK but fails on DVD burn step (Mac OS X 10.6.2).
I have the same problem with Burn2.3
Seems you're creating a DVD-Video disc with menu. Any chapters added? And how many menus are you using. This helps reproducing it.
Meant files instead of menus.
Tried to create a DVD-Video disc from one .MPG file (125 MB) - no chapters.
Seems to be a problem with theme loading.
Which theme are you using?
Can't reproduce the problem, might be fixed in version 2.4u.
If it stil occurs, please resubmit a bug with information to recreate it.