1. Yes, all audio and video drivers are up to date on both systems, as well as all windows updates.
2. On the main desktop I might check my email or surf a little during a burn but nothing more intensive than that. The second machine was built specifically to run roxio and burn dvd's so I can use my main box for gaming etc. I think bitorrent may be running on that Burning Box but I have tried shutting that down..... Someone in here suggested perhaps antivirus causing issue, shut that down, I've also got "adaware" running (free one on second machine, paid one on desktop) and have tried shutting that down as well--no change.
3. I'm not mixing separate audio and video, these are home movies taken off a camcorder or other wise movies that already have audio tracks on them. Not adding any text other than the menu, maybe I should try burning a dvd with no menu to see what happens? I have two somewhat new standalone DVD players, one is an off-brand region hacked machine and the second one is a nice (somewhat expensive) Panasonic jukebox player with the scan doubler function for playing standard dvds on a newer flat panel (and for the life of me I can't remember what they call that function). The Panasonic is also pretty new, have no problems playing commercial dvd's at all. I might buy what someone said about the player not having the buffers to have the information except that a lot of the older movies (with similar fps, audio formats etc.) I've burned play perfectly, just not new stuff on the same players!
Well the fact that you don't have this on vista 64 is reassuring because xp64 is the younger cousin of your os. The 2010 Roxio takes advantage of some functions in the ATI card that improve rendering speed, I've tried turning that on and off also...no change.
I just ordered another sound card, it's about the only thing other than the OS that both systems have in common. I think I may try putting roxio on my last machine still running xp 32 bit to see if it occurs there too. That machine is using the built in sound on a socket 939 motherboard. I'm also in the process of rebuilding an ancient socket 754 system but that one is also on xp64, but not AM2 or 3 which are really quite similar in many ways even if the one is a phenom. I'm hoping the different sound card may be the issue, guess I could also pop out the soundblaster on one box and turn on the onboard sound...just grasping at straws here now but this mess ruins my movies and if I want to sell anything this problem must get cured because no one will buy work with issues like this.
It's very weird, doesn't seem to be a rhyme or reason. I've tried looking at the stats of the problem files don't see any obvious differences in the fps or the size of the frame or the audio version or any such thing as that.....i.e. they're all over the place, I don't see anything consistent in the movies that are a problem vs. the ones that aren't.
Personally, I think microsoft broke something since it didn't happen till about year ago and now it does. Aggh keep swapping and experimenting. My friend has a AM3 with xp32 on it for compatibility with software reasons, I didn't think about trying a burn on his machine when I was up there, may take that file along on a thumb drive and see if it happens on his box too.
Lastly, I'm not creating the dark panel, it's part of the movie, i.e. the camera already put in the fades or it was already otherwise in the movie. This is a complete movie I'm having issues with, not something I created or edited myself.
One last thing, I tried shutting off indexing on the drive(s) just in case maybe that had anything to do with it; no change.