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What I'm hearing is that the file was corrupted in burn, probably because other processes took priority from the burn.
DVD writing is very processor intensive, and even with a solid processor and a reasonable amount of RAM, you could still be interfering. So make sure everything is turned off - aggregators, news feeds, even the airport/network. Don't do anything - not even solitare or bejeweled. Walk away from the machine and I dunno... do the dishes or something.
In Prefs, under Energy Saver, set settings for Power adapter and optimization for better performance. Set sleep to never, set display to sleep to never, uncheck spin down hard drive.
Use only DVD-R disks, not DVD+R disks. Yes, I know G5s are supposed to be able to handle +Rs... but -Rs are more reliable in a Mac. Lots of people swear by Verbatim disks; I use Fuji or memorex myself, but MacDev and MacSlash both have a lot of positive feedback on Verbatim. Try another batch of DVDs - bad media matters far more with DVDs than it does with just about anything else.
Clear your cache. If possible, do nothing else before burning. (i.e. Restart and do the burn first.) Onyx is freeware and is a good cache cleaner.
When you insert the -R disk and it asks you what speed to burn the disk, set burn speed to lowest possible burn speed.
Instead of using iDVD, since you have the file in .avi format, you could try a simple drag and drop onto the burn file disk, then burning it that way.
Hope this helps.
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