Well, after upgrading from Snow Leopard to Mountain Lion, doing a complete reinstall of Toast 11, and applying the latest update, I figured I try once again to get it to let me make an 80m CD. Here's a shocker...the problem remains. Nobody from Roxio or Corel or whoever's in charge these days cares to help me solve it so I did some more testing and at least came up with another data point about when it happens.
To recap, T11 insists that audio CDs are 650mb and wants to split everything more than that onto 2 CDs even if I have a 700mb blank inserted. Only trashing prefs and restarting gets it to see 700mg as the capacity of the CD.
What's new is this: If after trashing the prefs and getting it to accept 700mb as the size I burn a 700mb CD, then the next project will retain that and let me burn another 700mb CD. However, if I insert and burn a 650mb CD T11 then thinks that is the size of whatever new project comes next, and splits any content beyond 650 onto two CDs...even when I have a 700 CD blank inserted and ready to use. The only way to get it to recognize 700mb blanks again is to quit, trash prefs, and restart.
I think one reason some people haven't been able to reproduce this problem is they may not have any 650 blanks handy; they are much more uncommon than they used to be, but I still use them because for critical audio work they are a tad more reliable than 700s. So if all you have are 700mb blanks, T11 will never misbehave. It will always read and recognize 700mb. But as soon as you burn to a 650mb CD it writes some gobbledegook to the prefs file and considers every audio CD you want to burn from there on to be limited to 650.
Since this didn't happen with any previous version of Toast how hard can it be to isolate and correct it? Whether it's hard or not, nobody at Toast HQ has cared about it for over a year now. And I wouldn't be surprised if T12, if and when it comes out, will inherit this problem also.
Meanwhile, I'm hoping someone who's expert enuff at what's in the prefs file and can get their hands on a few 650mb CD blanks, can duplicate and/or isolate what's going wrong and maybe get the attention of the support dept. They aren't listening to me that's fer sure!