The 1GB chunks are part of the DVD specification. If you want one huge VOB you can use the VOB Passthrough option in DVD to Mobile. It used to be in Generic, not sure about the new versions. You can install it as a device so that it appears in the DVD to Mobile navigation pane using CustomizeUI->DVD to Mobile. There will be no menus, and your hard disc will need to use the NTFS file system to get big (>4GB) VOBs from long movies. There is some information about this in the Tutorial (click on the red "Official Guide" link in my sig).