DVD-9 breakpoint

I have a music doc/concert film project with 3 hours and 17 seconds of video. I have DTS and 5.1 AC3 sound. The DVDSP meter says I have 8.2 GB on the disc. Computer says 7.58 GB. I am preparing for replication.

I successfully burned a few copies on DVD+R and DVD-R. I have 7 different players for testing purposes. 6 play the disc without issues. One stops about 4 minutes before my break point (set manually at 93 minutes into the project). Menus total about 250mb, FWIW.
Most of the content is burned at 5mbps CBR.

Discmakers said to send them a DVD R and we'd be good to go. Their evaluator is getting an error message and says " It appears that either layer 0 extends past where the layer break is allowed to occur or layer 1 is larger than layer 0." I don't see how layer 1 could be larger. It not only has six minutes less content, but I also dropped the bit rate down a bit for some of the bonus material that appears on that layer.

Do authoring discs have less capacity than the 8.5G Ridatas I am using? I noticed that when I try to format to CMF or DDP on the hard drive, the DVDSP program says my 0 layer is too big.

Not when I burn to DVD-R or+R, though.

Scratching yet another hole in my head,

Jay