I just found all of my old project files (in 20 pieces) and I've found backups of all of the source audio files. This means I can get back into the audio mix and fix the problems (including replacing the bad dubs).
Work is starting, then, on a new and improved audio track that will synch with the original single-layer DVD.
If this is well received, I will also put out a dual-layer version of this with some video fixes (for example, to fix the inconsistencies with Mace's saber color, and remove some of the more radical use of temp footage).
-TM