I've looked at that thread, but had trouble getting that to work. I think it's because the mpegs were edited- if you demux the A and V via bbdemux, then run the A through again, it finds multiple streams there. Problem is if I ask it to demux those, it seems to do a length equivalent to the start of the show to the first commercial break, then stop. The audio that produces plays back as nothing but static.
Since I started this thread, an opportunity to work with CaptyDVD came my way, and it appears to be working. It's happy to import my MPEG1 files and preview them with synched audio, and when we do the Get Info equivalent on the file, the after encoding size goes up by just a dozen megs or so- seems reasonable to be the difference between 44.1 and 48.0 audio.
We ran out of free HD space to compile the disc, so as soon as we can get a spare FW drive on that machine, we'll know if we can render the disc.
And yes, I could go PC with this... I'd prefer not to.