Cannot Publish 1080 but 4K publishing is OK

Publishing to 1080 with a 2160 time line fails while the 4k publishing works.

Using Premiere 12, I successfully published a 5.7gb MP4 H264 3840x2160 29.97P 30Mbps using the XVAC-S to Computer publish function.  It created the 5.7gb file which I copied to a memory card and played it OK on my 4K UHDTV.  The originals photos and videos clips were 3840x2160.  Premiere input setting were Red Camera 3820x2160; 30 fps non-drop, capture DV; video render:optimize stills. 

However, from the same time line, I want to Publish a 1080 file for 1080 TV's and for DVD players that only read 1080.  So I tried to Publish using the AVCHD MP4 1980x1080p 30 command MP4 1080P 30Mbps.  It went through an hour of rendering OK.  But then had a fatal error at 3% when burning to the computer HD.  I tried this twice.  Both times same fatal error.   In the past, this Publishing from 4K to 2K always worked.  However the files were under 4gb.

I also tried inputting the published 4K file and create a new work using it as a single file.  Then using the same AVCHD 1080 Publish Command, tried to create the 1080 file.  Failed this way too,  It rendered OK but failed at 3% when burning to computer HD.

How do I correct this problem and create a 1080 file?  Note that I did not try to create a disc menu in any case.

As an alternative, is there a program that would just convert the 4K video to a 1080 video without using Premiere?