Have you tried loading the output from iTiVo (whatever format you selected) into a DVD authoring program? That should make a valid chunked vob for you (or just burn the DVD for you entirely). The DVD format (and in fact, most mpeg2 formats) are giving me a nasty headache, they work for some inputs and not others... I've mostly given up on doing anything about it, but if you figure out mencoder options to make it work, I'll gladly incorporate them. One thing to make sure of though: If the encode didn't complete cleanly, the file is almost guaranteed to not work (there's some header information that isn't written out until the encode is completed).