I have tried to rip Shrek the same way as I do with all movies that are over 4.38 Gb.

1. Only selected the movie and the 6 channel dolby sound

2. Chose to demux both to a file

After ripping is complete, the new *.m2v file is only 50 mins long instead of 1hr 25mins (or there abouts)

Before I begin ripping, smartripper informs me that it requires just over 5 Gb HD space but the ripped files only actually use about 3.7 Gb

I've tried ripping again but have had the same output.

This is really doing my head in.

Please help.

yes. all i did was change one setting max file size, and change the max file
setting to 5.6gig. hope this will help. good luck.