im sort of having the same problem, i added my subtitles, synced everything, it works fine on my computer, but when i burn it and play it on my dvd player, there are these blocks of gray squares scattered all over the screen. but when i play it on my computer, its fine. and i used subtitle workshop, virtual dub and then i used nero to burn it. the movie is an avi file, the sub's are either ssa or srt i forgot and ..also about 20 mins into the movie, the audio and video arent sync anymore. but it was synced when i watched it on my computer..whats happening?!
op wants subs on dvd you want it on avi? dvd try convertxtodvd on merge tool before encode avi not sure?
