Do you have a old non working DVD still? Did you fill data greater 4GB to DVD?There is a sector address limitation. Early boot files has to be below 4GB sector address. 4GB sector address limitation occurs twice: textmode: setupldr. bin read files from DVD. Once cdfs.sys is loaded and active, hole DVD is readable. first reboot: at end of textmode hivesys.inf disables cdfs.sys. Driver is not loaded at first reboot. Next asms files are read. This fails, if asms files are at end of DVD media. At PNP drivers are loaded, cdfs.sys is activatet again. Hole DVD is available. Cdimage sort directory deep levels at end of image. Asms is a deep directory. Cdimage I386 sort directory I386 only, no sub directories. If you add own files, use a deeper directory. Mkisofs dosn't sort by directory level. File sort from operating system is used. If you add own files, use a directory name at end of alphabet, e.g. \Z_add. Or use mkisofs -sort. 4GB sector address is a limitation inside setupldr.bin and ntldr. At some BIOS there occur a limitation at 2GB sector address.