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Get the mpeg2 file off the Replay using DVArchive.

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Run it through evtdump:

  evtdump source.evt > source.evt

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Use rtvedit to chop it up into separate files for each chunk between commercials:

  rtvedit source.evt

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Use rtvconvert to demux the stream:

  rtvconvert -d source.mpg dest

This will generate two files: dest.m2v and dest.mp2

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Generate a DVD compatible mpeg file:

  mplex -t DVD -i ES_STREAM -o dest.mpg dest.mp2 dest.m2v

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Create a dvdauthor XML file to define the structure of the DVD.  Example:

<dvdauthor>
    <vmgm />
    <titleset>
        <titles>
            <pgc>
                <vob file="dest.mpg" />
            </pgc>
        </titles>
    </titleset>
</dvdauthor>

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Create the DVD filesystem:

  dvdauthor -o dvdvol -x dvd.xml

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Create the image to burn to DVD:

  mkisofs -dvd-video -o dvd.iso dvdvol

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Burn the DVD

  dvdrecord -v -eject speed=4 dev=0,0,0 -dao dvd.iso