Ripped a few movies then burned them to DVD +R and the Z1 plays them perfectly. Ripped one ( Pirates of Caribbean 2 ) to DVD - which needed to be Dual Layer - the unit won't play it. Plays in my home DVD player though.

Anyone run into this as well with DL DVDs ?

No problems with DVD+-R DL on my unit. You dont have to put Pirates 2 on a DL disc. I used CloneDVD to shring it to 4.7GB for a regular DVDR disc. You can also use DVDShrink as well (the latter of which is freeware). I have not seen any negligible loss of quality shrinking Pirates 2.

What brand media are both of you using?