Hey all, thanks for the feedback.
For clarification:
I'm burning an audio CD.
Many of the tracks are sound bytes or samples that transition to the next song. That's why there are so many because they are short.
Crossfades and edits become important because the mix is mostly continuous.
However, it's important (to me) for the listener to be able to skip ahead if needed.
I'm still testing all of your various suggestions but here's what I've learned so far:
Toast seems to indicate that there is enough space for the lead out but I deleted a track to make space and it still failed.
I was using Memorex CD-Rs and tried a Verbatim disc, still failed.
Recently = I've never had this issue before.
I saved out an .Sd2f file and it also shows the tracks but they are silent.
When I burn the playlist directly form iTunes (i.e. with no crossfades) the disc burns correctly. That would indicate something is up with one of the tracks or with some sort of crossfade issue but I have no idea how to test that.
Again, thanks for your help so far. Other thoughts?