Hi Samlar,
Yeah I figured it'd be my luck to have the same disc from both sets have the same problem, and the episodes on it were the same ones as on a missing disc from the local video store - DOH

Anyhow, Amazon are reluctant to send a 3rd set lest it is faulty as well; can't blame them cause the postage to Australia and back can soon remove any profit they make from the set. So I'm now seeking replacement discs from the manufacturer, gonna try anyway!

The US region 1 discs have each season spread over 5 discs; whereas the region 4 set in Australia are spread over 6 discs for the first 8 seasons, then over 5 discs for seasons 9 & 10 - result is some episodes are on different discs to the region 1 set - episodes are still the same order, just some are on different discs ??

What I'm wondering - is there some software that'll let me re-build/fix the menu? then I can simply burn a new disc that works.