Dayum! I was hoping that Popcorn gave you the option (as Toast 7+ does) of making a dual layer disc image but it seems it doesn't. If you can get access to Toast 7/8 then you could try. What happens when you try to get DTOX to do the full disc copy ?
We can now discount media/hardware error so I'm betting on the structure. If it really is borked then you could just compress the whole shebang by a really small percentage with DTOX. That way you'd get it correctly formatted but the change from the original would be imperceptible.
Hey, at the very least you've ended up with much more widely compatible firmware on your drive
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