Guy,
I'm sorry if I am getting down to basics here. There is still some confusion on my part on what is set in your project and what isn't.
Rebuilding the project from scratch may be easier than trying to go through all possible places where this or that may be set wrong. If you haven't saved your menu as a .psd file to the Library, please do so now.
Then start a new project:
1. Import the .avi file as a timeline.
2. Add the menu from the Library via the New Menu button at the bottom of the Library panel.
3. Set each chapter in the timeline (except the last one) to have an end action to return to the menu. Ultimately, each of the individual chapter buttons on the menu will link to the appropriate chapter in the timeline. This will produce playback of each chapter with a return to the menu.
4. Create a single Chapter Playlist with all 4 chapters listed in order. Give the playlist an end action to return to the menu. This will be used for your Play All function.
5. Link the Play All button on the menu to the Chapter Playlist.
6. Link each of the chapter buttons on the menu to the corresponding chapter in the timeline. That will eliminate the Orphan Timeline error during Check Project. Disable Sync Button Text and Name for each menu button
unless each chapter in the timeline is named appropriately. That will keep Encore from changing your button text when the link is established.
That's it. You're done. Preview, Check and Build.
HTH,
Jeff
The Focal Easy Guide to Adobe Encore DVD 2.0