Is it possible that VS11 was re-rendering? ...Maybe VS11 recognized something "wrong" with the files and treated them as non-compliant???
There could be an issue with the high bitrate. (VBR means Variable Bit Rate and I don't know if 9100 is the average or maximum.) The DVD spec allows a maximum video bitrate of 9800kbps with a combined video, audio, and subtitle maximum of 10,200kbps.MPEG-2, VBR 9100, Dolby Digital 5.1 (bitrate 448).
You can estimate average bitrate with the following formula:
Bitrate = (140 x File Size in MB) / Playing time in minutes
If that formula shows you have a combined average audio/video bitrate of around 9500, it's a good bet that your peak bitrate is out-of-spec. If your average is less than 9000, then 9100 is the peak bitrate and you're not out-of-spec.
But, some DVD players apparently have difficulty with high-bitrate "burned" DVDS. The usual recommendation is to keep the bitrate below about 7000kbps.
You might try shooting some experimental footage with your camera at a lower bitrate to see if that will solve the problem on future projects.
There is a chart here that shows no quality improvement when you go over 8000kbps (with standard definition MPEG-2).
