"failed to reuse converted cache" when creating IS

[spyros]

I'm getting the dreaded "failed to reuse converted cache file" error any time I try to output a simple project and create either the VOB files or an ISO file. 3 Ghz system, over 150 GB fee disk space for temp and output directory, 2 Gb RAM, virus protection turned off. DMF 3.5 suite, latest patches applied. WIndows XP SP2, fully updated. Deleted temp directory, bunch of .DAT files in /my documents, etc. Any suggestions?