Kwag,
You've helped so much & I'm almost there

. One more hurdle to go.
I previewed the m1v made by TMPGEnc in Power DVD & it looks ok. The mp2 generated by HeadAC3he (AC3->mp2) plays fine in Media Player. The problem is bbmpeg won't mux them! It makes a mpg (without any errors!!!) that appears to play fine in Power DVD but there's no audio. It's obvious too cause the mpg is only 2-3mb bigger than the m1v. Media Player won't play the muxed mpg at all but it will play the m1v and mp2 separately.
bbmpeg settings were:
Program stream type: VCD
VBR: checked
Write program end code: checked
No other check boxes
Forced mux rate (in 50 bytes/sec units): 0
Pack options, Buffer sizes, and Startup delay all per screenshot
I'm thinking of trying bbmpeg again with VBR unchecked. The mp2 is also a 160kbps VBR dual channel; should I have made it CBR?
melmo