Here's an update to my saga.
I did several tests: cut out accelerated clips, use another menu template, uncheck "include root menu" and "include opening menu video", etc. All unsuccessful.
After reading other posts I thought related to my issue, I tried what one of the posters said "worked" for him: specify "no menu".
Doing so, my project successfully completed a Create of an ISO. Having "no menu" defeats the purpose of a 1.5hr Blue Ray with 8 chapters, but at least this test sort of points me to a next step in debugging this issue.
I have long chapter text fields that overlap somewhat the thumbnail (World Monopoly template). So I'll try shorter text not overlapping and fewer chapters per page.
I believe there is a great opportunity for CL to clean up code logic: throughout these numerous tests, I've seen all sorts of strange behaviors. Why loading a project that has not changed a bit now throws CL into a 'not responding' state, while killing the process and reloading the project works perfectly well? Why do I get an error immediately at the start of a Create when that Create goes just fine after restarting CL?
CL has put in a tremendous set of functionality into PD over time. I think it's now time to clean up by coding for the exceptions.
I've often read that corruption in a movie can produce all kinds of strange behaviors. If this is what prevents me from completing my project, then I would recommend (already addressed to CL development)
1- more robust coding so that specifics are provided as to what is corrupted thus facilitating corrections; when PD13 aborts giving a cryptic error code, surely it has specifics as to what it didn't like
2- better yet, even more robust code that circumvents the corruption with a warning and completes the project
3- some utility that scans a project and its time line to detect corruptions
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