Using the latest KVCD template... I'm new to this, so there is a very real possiblity that I goofed this up. I'll explain what I did, and hopefully someone can tell me what I did wrong.

1. I have two .avi files (~700meg each) of a movie. They are a screwy resolution (640x352).

2. I opened one up in FitCD, said it was a 1:1 (VGA) movie. Told it that I wanted a 1/2 DVD (352x480) with a 4:3 NTSC aspect ratio (I made a few test clips to confirm it looked right on the dvd player).

3. It said to crop it to 640x350, then resize it to 352x350. I chose to center it (keeping aspect ratio) for a res of 352x480.

4. The files finished, but the total size is 471meg + 460meg. This seems to have well overshot an 80min CD.

Anything wrong with what I did above? The test clips I made look just fine (after many flubs) so I'm pretty sure the aspect ratio is fine. Again, this was done with the latest KVCD template (CQ = 70). No big deal if "that's the way it is", but if I did something wrong, would love to correct it. Thanks.

You didn't do anything wrong Daagar.
The problem is the avi's.

Read Q-24 here:
http://www.kvcd.net/forum/viewtopic.php?t=68

kwag

Ah ha! I had read the FAQ and the warnings about doing DivX conversions, but I only read the quality part, not the size part. FYI - the original source DivX was _really_ good quality for what it was (640x352), and the resulting kvcd was equally excellent, with minimal (if any) loss of quality in terms of macroblocks or blurriness. And this was all without AviSynth, just a straight tmpgenc conversion with your template. Can't wait to see your newest version!