DARN!! Sorry people! Just when I thought I had it all figured out and workin!!
Seems that this OOS bug pops up every now and then. The other day I captured an old movie. I goofed and file was too big for single layer dvd so I burned it to a dual layer. Audio was NOT out of synch, even at the end.
But then I just captured an 87 minute show, and it was out of sync AGAIN at the end. Started being visibly OOS even towards the end.
The only differences are
1. in capture settings was the bitrate, "frame-based" vs "UFF", & audio hz settings, and:
2. used another (older capture card and system) for the long movie that turned out ok:
Using the ATI software on an older ATI All-in-Wonder 128 Pro:
At 8000 kbps and Video type shown as MPEG-2 Video, there is NO out of sync problem. The Project Properites for this video shows "Frame-based" although I KNOW the video file BEFORE burning was "upper field first" as it was captured using AIW ATI software and ALL clips using that shows as UFF. VS must have changed this during burning??????

And this older version of MMC will not record @ 48000 hz, so 44,100 was used and is indeed listed in the file properties. This older system has a SB Live sound card and the newer machine has the AudigyZS.
The show at 6500 kbps and video listed in properties as MPEG-2 Video, Upper Field First. Project Properties for this was the same as for this one I used Trevor's idea on how to make sure the burning phase properties are the same.
The only other difference was that the long movie was recorded on the P3 system, I simply moved the large file over to the P4 for burning. The shorter 87 min w/ the OOS problem was captured on the P4 listed in Profile.
WHAT GIVES?!! I am hoping this has more to do with the compression rate than the machine/capture card used.
It's the same old problem again. Large Project file is fine all the way through, but burned DVD is NOT. Also stored the .vob files on disk and when played directly in PowerDVD it is out of sync the same as the burned dvd (this seems normal - if dvd is oos than so should these video_ts files)
I am really stumped on this. Should I just capture using the lower 44100 hz in all cases? Should I try using LPCM instead of Mpeg audio? Should I just use the older P3 and the older MMC software to capture from now on and move the huge file to the other for burning? Or should I just record the audio and video separately? (don't know how to do that but I sure can learn) YIKES this is NUTS.
Meanwhile I will try to capture using the older huffyuv codec in Avi but it still creates approx 30 GB per hour drive usage.

I tried Microsoft Video-1 like Trevor suggested but it was horrible looking. Really pixilated. Of course, that was using the newer MMC ATI software. I'lll try it in VS to see what it looks like.