When you swap to a burned game, the burned game has to be so big or the laser won't read the disk and boot it properly. You can fix it theoretically by taking apart your image and adding a "filler" in the beginning called a dummy file(any file that is big will work) then putting the image back together and burning it as usual. The dummy file will push the data further out and fill up the CD, but it's a bitch to do -- frustrating and you'll probably waste a lot of coasters. If you're not stocked up on CD-R's, I wouldn't waste my time even researching how to do it. If you really want to attempt it, you can find some dummy utilities meant for Dreamcast .BINs here; http://server1.megagames.com/dc/dc_utils_disk.shtml (I'm looking at Dummy Add v1.2 with the Dummy Add FrontEnd v1.2) .. I'm sure they'd work, as it just inserts a file into the image.
Just get a chip?
