*** EDIT ***
I just found a really good guide that will probably answer my question...have yet to read it.
I hope it's okay to post links to other forums here...I didn't see anything about it in the rules:
http://forum.doom9.org/showthread.php?s=&threadid=56020
*** ORIGINAL POST ***
jorel, thank you for making me do this test again.
I did it again, with an older version of DVD2AVI, but then I did it again with DGIndex and both results were good!
What I failed to mention was that I trimmed the audio with BeSweet. The last time I used the built in AC3 encoder. (I don't have the command line any more) This time, I used "Payload" output to trim the clip.
So...BeSweet was the culprit. It threw me off, because both output .AC3 files sound EXACTLY THE SAME in Media Player, but when used to mux a title set, the volume is drastically different.
I believe it has to do with BeSweet not creating 100% DVD compliant AC3 files, as I believe I read somewhere.
Sorry if I wasted anyone's time...the original problem is solved. However, if I want to do anything besides trimming my audio ("Partial Encoding" setting), "Payload" output will not work. Does anyone know a better solution for re-encoding AC3? (I guess this topic now applies to a different forum, but maybe someone can help here instead?)
Thanks!