It was a video for my friends band that they played at a show. All assets were captured using a Canon A520 digital camera (recorded directly from TV screen) and then imported as AVIs. I'm kind of sketchy on the whole codec thing/terminology. I burned one copy to standard DVD using Encore and exported as Quicktime (mov) file. For the quicktime file I ended up having to use Media Encoder b/c Premiere kept crashing.
in MediaEncoder you can choose the codec you want it to use. Codecs like h264 give you smaller files with high compression. By adjusting the data rate you can
control the quality and the size of the project. There is also a filesize caluclator that estimates the file size in the media encoder and it adjusts to the data rate you
If you want to burn it on a DVD you can also chose the right codec and container which would be an mpeg2 (video) and ac3 (audio). This usually lets you select
an option with "best for 60/90/120mins of video". Or you can adjust the data rate to the max. DVD capacity.
The scaling or multi layering is not a problem for the file size of the final output. Everything will be rendered to one video and audiostream (unless you export Stero or 5.1 Audio).
I reckon that the problem is the length of the video. 45mins is quite long so you might have to split the film on 2 DVDs or a double layer DVD if you want better image quality.
If this was recorded on a A520 digital you probably have 1920x1080 resolution? why did you size it up to 600%? This results in a huge quality loss!
Please give more information about the conversion to AVI and resolutions you use to edit (sequence settings) and the original resolutions of the files.