Here are the detail steps in preparing customized menu, replacing the menu, and reroute button commands to point to specific chapters. This should be general enough for anyone to follow and use as a reference.

Tools used: Subrip, MuxMan, DvdReMake Pro, graphic editor

First, let's start preparing the customized menu before replacing over the original one.

1. Extract the menu background ("Export frame" in Preview window). Modify in your graphic editor. Save as 24-bit BMP.
2. Open SubRip. Click on VOB button. Choose radio button "Save Subpictures As BMP" and untick the Options checkbox. Click on Open IFO button. Select the corresponding IFO for the menu VOB, in your case, VIDEO_TS.IFO. You should see VIDEO_TS.VOB automatically checked.
3. Click on Start button. Choose a filename, e.g. subpicture, to save in the created menu folder. Click Save.
4. Under Colors tab, choose Sonic Scenarist preset. Do not check "Custom Colors and Contrast". Make sure 4 bits is selected in drop down list.
5. Under Cropping tab, choose size constraints: 720x576 for PAL, 720x480 for NTSC. Choose XY alignment to be center.
6. You should already see the subpicture bitmap - red background and black highlight. Click OK button. A file will be created - subpicture.1.bmp. If there are multiple menus, you should see a sequence of files.
7. Modify this subpicture bitmap in your graphic editor, aligning the black highlight to cover the button text in the menu background. With the subpicture bitmap as the first layer and setting the transparency temporarily so you can see the background to align is very helpful. I'm doing this in Photoshop, so I don't know if PaintShopPro has this capability. If using Photoshop, save it as OS/2 format, 4-bit. Save it as SUB.bmp. The attachment below shows the modified subpicture bitmap.
   
   Now, let's combine both the modified background and the subpicture bitmap to make it into a VOB format to replace in DVDRMP.
8. Create a script file, SUB.sst, with the following content for use in MuxMan.
   
   For PAL:
   Code:

   st_format    2
   Display_Start    forced
   TV_Type        PAL
   Tape_Type    NON_DROP
   Pixel_Area    (2 574)
   Display_Area    (0 2 719 574)
   E2        (255 255 255 = = =)
   E1        (0 0 255 = = =)
   PA        (0 0 0 = = =)
   BG        (255 0 0 = = =)
   Directory    .
   Color        (1 1 1 1)
   Contrast    (0 0 0 0)
   1        00:00:00:00    00:00:00:00    SUB.bmp
   #

   For NTSC:
   Code:

   st_format    2
   Display_Start    forced
   TV_Type        NTSC
   Tape_Type    NON_DROP
   Pixel_Area    (2 479)
   Display_Area    (0 2 719 479)
   E2        (255 255 255 = = =)
   E1        (0 0 255 = = =)
   PA        (0 0 0 = = =)
   BG        (255 0 0 = = =)
   Directory    .
   Color        (1 1 1 1)
   Contrast    (0 0 0 0)
   1        00:00:00:00    00:00:00:00    SUB.bmp
   #

9. Open MuxMan. For Video, select the modified background BMP. For SubPictures, choose SUB.sst. You can add audio if you want. Choose the destination folder. Click Start.

Now for the fun part - replacing menu in DVDRMP. Well, I could replace the menu over the original one as mentioned in post #32. But then I have to write a lot of commands to point to a specific chapter. So I'm going to use method #2 and comletely reauthor the DVD to make it as simple as possible.

1. First, let's start from the beginning. Assuming that you have already splitted the cells and created the appropriate programs. Since you say that program 1 is undesired, then "Delete program and block(s)".
2. Create chapter for each program. Do this in the Titles pane. Choose "Add chapter" and multi-select the programs.
3. Now, let's get some needed info before replacing. Go to Title menu, CLUT pane, export the CLUT (Color Look Up Table containing a list of subtitle colors in the IFO), name it CLUT.clt.
4. In the Preview window, select "Edit color schemes" and export, name it colorscheme.mct. The color index number for each pixel type (e2,e1,p,b) refers to the color index number in the CLUT.
5. If you have saved a project, containing the 16 buttons, you can export the buttons as well, name it modified_buttons.mbl; otherwise you have to create it after replacing the menu. This file contains the button positions, button commands, and button directional links.
6. Go to VTS1/Menus/PGC1/Programs pane, select "Add program".
7. With program 1 selected, choose "Replace block". Hit Load button. Choose the VTS_01_1.VOB that MuxMan has created. You should see the modified background. Hit OK.
8. Double-click on program 1 and choose Still time to "infinity".
9. Now let's import the info what was just exported. Go to CLUT pane and import the CLUT file.
10. Go to the Preview window and import the buttons file. If you don't have buttons, you have to create them, making sure that button rectangle markings cover the button highlight - you just have to guess.
11. Import the color scheme file.
12. Enable the subtitle track so you can see the button highlight. Go to Menus domain, Subpicture Tracks pane, select "Add track" and OK. Then go back to menu PGC 1, Subpicture Tracks pane, double-click on Track 0 and check "enabled" and OK.
    
    Now to clean up and rewrite commands.
13. Go to DVD node in DVD tree, select "Remove navigation" and "Enable all operations".
14. Go to Video Manager/Menus/PGC 1/Programs pane, select "Delete program and block(s)". You don't need it.
15. Delete VMG PGC 2 & 3 as well.
16. In First Play PGC, add pre-command Jump VTS 1 "root" menu (title 1) (Jump/Call Instructions).
17. In Video Manager/Menus/PGC 1, add pre-command Jump VTS 1 "root" menu (title 1) (Jump/Call Instructions). You can copy the command in First Play PGC and paste it here.
18. In VTS 1/Program Chains/PGC 1, add post-command Call "root" menu (resume cell 1) (Jump/Call Instructions)
19. In VTS 1/Menus/PGC 1, add pre-command highlighted_button = 1024 (button 1) (System Set Instructions/System Set drop down list).
20. In the Buttons pane or Preview window of the menu, fix each button command to jump to a specific chapter, e.g. Jump Title 1 chapter 1 for button 1.
21. Export, test and enjoy your custom made DVD.

That's it. Looks long but really not that hard once you get the hang of it.