I got the dvd burned. There was an uncompressed file called tools it was 300 meg. Mostly open source stuff for windows and German documentation. I removed it. With the extra space I put in evolution and quake 2. At 1.9 gig I could copy it to the fat 32 partition, then open windows and copy the iso over into my NTFS and burn it with Nero.
The problem remains though. I want to eventually be able to burn an image greater than 2 gig and I want to try avoiding a bootloader. Ideally I would like to be able to boot my remaster with a floppy from where it resides on the disk and burn the DVD with kb3. can anyone help?