I do this by using WinZip to make a single archive file of the entire disc and then burn that to DVD.
My confusion comes from the fact that, although very few files have changed significantly and I do not download much, the time taken to burn is all over the place. One time it will be 20-25 minutes and like today when it took about 43. It will be something else next week.
I am running XP Home + SP3 and have 1GB RAM
Burn is done with Nero Express and nothing else is ever running at the time.
If you check in Nero .. and do a Multi-Session burn, you can tell Nero to just replace new/changed files. You would not use Winzip then tho.
However, Nero buffers small files before burning for quality/safety.
That may be the reason.
Try always rebooting before burning the file(s)