The process you should be aiming for in making a Data CD is:-
Pre-mastering data , which means setting out the data to be written in a logical fashion.
Select the type of image to write in the Image tab page.
Enter the target filename and path plus the source path in the Target tab page and enter
any settings which apply on the Writer Settings page.
Next check the size of the proposed image using Test Size button on the Sources tab page.
You need to allow space for Table of Contents etc and a rough rule of thumb would be that 615 - 620MB of data image
using Rock Ridge extensions will get close to the limit for a 640MB CD when written to disc. Always experiment with
a dummy write before burning to CD.
If you use Joliet as well this overhead is increased and dummy writes are definately required to make sure it will fit.
(Avoid using Joliet if possible. It is not actually required for most modern operating systems (even Windoze). It cannot cope properly with duplicate file names and not at all with symlinks.)
Then make the image.
Output from mkisofs will be displayed.
Always check through this output, it will be your first warning of problems and will give an exact size for the image.
The next stage is Checking Image files. You can browse the file system of the image just like
any other mounted device or partition and ensure all is as it should be. CD-Rchive2 mounts and displays the image for you.
The golden rule here is if it won't mount, don't write it ( unless it is a Multi-Session CD)
Penultimate step, ensure the Dummy Write option is set, check other settings and do a test write. Check the output from cdrecord and
if all appears OK;
Final step, write to CD!
Making a Data Image