While I can't remember the exact filename, I feel pretty confident that a DVD is out of the same file. This was not too new or old.... Pretty much there is no such thing as too new as the group will need a source to make the encode.

I very much doubt he is using the right settings as I have never heard of anyone using fit to disc and the finished result not fitting. Either that or the DVD-r disc being used sucks.

A 250GB download limit is quite nice. Lots of people are more unfortunate.

I can't remember the last time I transcoded .avi to DVD to be honest. I just connect my Laptop to the TV and Stereo and viola

I was referring to a screener posted only as an AVI, which he was trying to encode. Since "Zachary Zipper" is currently playing at a theater near you, it is indeed too new to have had a commercial DVD release.
I agree; the only way I could approximate his problem was by changing the DVD capacity to a DVD-1, and I did warn him to check that Nero wasn't set on that. Maybe he thought DVD-1 meant "fit onto one DVD."
True, and I'm not complaining; someone who needs to d/l more than one DVD per day should look seriously into getting a life. But if your ISP has more draconian limits you may well decide to d/l the AVI file and invest a couple of hours at home transcoding and burning it to a DVD (assuming you need DVDs because you're not fortunate enough to have a laptop with a large HD that hooks up to the TV and stereo), rather than use up your precious bandwidth GBs.

You are right about there not being a DVDr source in this case... well not released at least. .mov source for the encode.

But this is highly uncommon. That .mov source would normally be DVD source.