It was the LPCM audio that was upsetting everything.
I demuxed the VOB streams using DVD Decrypter and first saved audio as LPCM and then did it again after selecting the "save LPCM as WAV" option under the stream processing submenu.
I got my 3 streams......
.M2V video file
.PCM audio file
.WAV audio file
First, I remuxed the .M2V and the .PCM using tsmuxer and output a .m2ts file
Secondly, I remuxed the .M2V and the .WAV file and output a second .m2ts file
I fed each in turn into TOAST and output a BD image to the HDD using the NEVER re-encode settings and PCM audio selected
*** side question.....if I select NEVER re-encode, is this for BOTH audio and video? or just video?? I have a feeling it might be both?? **
The resulting output was:
the first stream once again FAILED - skipping in all the same spots as i expected
the second stream WORKED!!! PROBLEM SOLVED!!
This has added a lot more work to the project, but at least I know that it is a problem with TOAST and LPCM audio. When using .WAV uncompressed instead, it works just fine.
Now ROXIO, any chance of a bug fix??? ;P
I'm happy to provide the offending PCM audio track if anyone wants to try a fix....
Now, does anyone know of a nice, easy to use batch VOB demux tool that allows remuxed file output in VOB and M2TS file format?
Thanks again for the suggestions tsantee.