OK I’ve had time to play with the vob/dvd system using Full Metal Panic and I have to say I’m happy with it so far.

Using DVD Shrink to remove the menus and languages etc I created a striped down .vob and copied to the drive. Initially I had no sound but after punching the “Audio” button I got audio to appear under the audio selection “82” And all working (striped fill comes in at 1.3 ish gig).
Next I copied all the files of the disk to the hd (extracted with DVDDCSS) and using the “DVDplay” option I played the files as a dvd and all worked without messing around with audio tracks.

Haven’t got around to xvid yet (only got a 10 gig hd in the drive) but will try that out later.

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