Stanley,
Unfortunately, I could only test this on EncoreDVD2, not CS3. I went through your first two tests, and each time Encore built to a folder (played fine on Cyberlink PowerDVD) with not a problem.
For Test 1, I created a new Project. Imported the AVI, as a Timeline. Imported Sunset and did Edit in Photoshop, to remove unused Buttons. Saved back to Encore. Linked Menu as Play First and its Play All Button to the Timeline. Set End Action on Timeline to Return to Last Menu. I tried this both from the drop-down and with the Pickwhip, just to make sure. EncoreDVD2 built to a folder perfectly, regardless of which End Action setting method I used.
For Test 2, I created a new Project in a new folder. Imported the m2v as a Timeline and the AC3 as an Asset, then added the AC3 to the Timeline. I then Imported Sunset and did the same Photoshop editing. Back in Encore, I linked the Menu as First Play and its one Button to the Timeline. I set the End Action of the Timeline, both with the drop-down and the Pickwhip once more. Again, EncoreDVD2 burned the Project to folder perfectly with both End Action methods.
Rather than trying your Test 3, since both 1 & 2 worked perfectly, I recreated the necessary structure to run your Clip1avi.ncor. As I didnt have your modified Sunset Menu in that structure, I got a placeholder Menu, but replaced it with the one from the Library. I did the same PS work, and Saved. I had to point Encore to the Clip1avi.avi, as my structure was obviously different, than yours. No problem, Encore accepted it. I linked everything as per tests 1 & 2. However, on Check Project, I got the Menu Remote Not Set error. Heres where it got odd. When I clicked on the Menu Remote setting in the Properties Panel, I got the dreaded Sorry, an abnormal condition has been detected. Before quitting, you have one chance to save your project (dont use the same name as the original). I did a few Save_As, and tried the Pickwhip for the Menu Remote - same error. I closed, and opened on of my Save_As Projects. Same error. I tried all variations of Saved Projects, but all yielded the same error. I went ahead and did a Burn to Folder, ignoring this error message. Though the Menu Remote was not set, the Project Burned perfectly.
I do not know if this additional little problem came from MY building the folder structure for your .ncor file, or if there is something amiss in your .ncor file. I would suspect that it is something in the way that I set up folders. Maybe I missed something necessary for Encore. I will assume responsibility for this one. Out of curiosity, did you get that error in your tests?
Im sorry that I did not get the PGC error in any of these. I also listed things in the exact order that I did them, in case that has any bearing on the problem.
Ill keep these files around on the workstation, just in case you need for me to try something else.
Computer:
3.5GHz Duo-core Intel
4 GB Corsair Pro (4x1GB) RAM (3GB switch)
4x 1TB SATA II HDDs
1x 1TB ATA-100 HDD
nVidia Quadro FX4500-512
Creative SB 5.1 SS
XP-Pro SP3 (latest patches)
Adobe CS2 (remember, Im on CS2) Production Studio
Good luck, and let me know if you want me to try anything else,
Hunt