I've got a 7.9GB already-transcoded video file, and a 297.8MB already-transcoded audio file, both set to 'Don't Transcode' in Encore.
Despite this, Encore reports the 'Encoded Size' for the timeline containing those two assets as 9.093GB, conjuring a GB from thin air and rendering my project unburnable.
I've had this problem before, but it stopped happening. It's happened on both of the projects I've tried to create this morning. I have no idea what's causing it, or what made it stop.
There are three other timelines, all of which appear to be doing the same thing, though to smaller degree since they're relatively tiny:
72.39MB (2.8 audio 64.1 video)
14.51MB (609KB audio 12.8MB video)
20.2MB (829KB audio 17.8MB video)
What on earth is going on?