Ok the layer break (the one I set in DVD Studio Pro) is at Chapter 22. There can only be only layer break in the disc so I am not sure what else you guys are seeing. Weird.
Ah.... I may have found the problem!
" Finally, the break point, when using -R media, will be defined as Seamless which may cause incompatibilities with some set top players. Using +R media generally provides more compatible output."
I think the copy I sent to Darth Solo was DVD-R DL media!! Actually maybe it was +. Oh dear I can't remember.
I am burning a DVD+R DL disc as we speak. I will test it on a number of players and get back to you.
JD