I just built a single layer DVD that hit the ceiling in DVDSP.
It said I was at 4.7 G. It burned okay and plays on my home DVD player just fine. But my client queried if maxing the disc out would hurt performance. He mentioned that when creating music CDs that they can have trouble playing sometimes when all of their space is used.
Is this an issue with DVDs or am I safe to send this to press?
If you're replicating, there's no problem with filling it up. But your client is right if your final destination is DVD-R. 5%-10% of the outer edge of DVD-Rs are prone to errors, and while some players may correct them, many will not. I never fill my DVD-R-bound discs beyond 3.5-3.7 gigs. As always, it depends what you mean by press - if you're replicating from DLT, you're fine, if from a DVD-R, all you're getting back are more DVD-Rs, not DVD-Video discs.