I have been using flick for almost a year now, it seems to be getting better and better.
I have found it to be consistent in hitting the desired target size and handling audio very well. It's never gone over 4400MB. Switching to low priority mode on the fly allows a little light multitasking even with a single core cpu. If your source is higher quality try to stay around 2 hours of video, you can go up to almost 3 hours on average video. The last few months all my tests have stayed in synch very well.
I always save to the hard drive and burn manually so I can check flick's output every now and then or be able to burn more than one copy. Keep an eye on the target drive tho as it tends to get heavily fragmented.

Also double check any pal/ntsc setting after upgrading. The program is really a "work in progress", but a wonderful one.