Build a burnable disk image from a blu-ray disc folder structure with Automator
(an Automator solution)
To create the Blu-ray disk image
1. Launch the version of the Automator workflow appropriate for your system: version 1 for Leopard and Snow Leopard, version 2 for Lion and Mountain Lion. (Important: for Mountain Lion, you'll need to change "Folders" in the third action, "Ask for Finder items", to "Files and Folders" using the pop-up menu for the action. QuickTime for Mountain Lion makes the system see the BDMV folder as a file.)
2. Put your BDMV and CERTIFICATE folders inside a folder having the name you want for your Blu-ray disc.
3. Run the workflow, select your BDMV when prompted, then, at the next prompt, select an output folder where your disk image will be saved.
4. Terminal willl open and the disk image will be created.
5. If your disk image is small enough, you may be able to burn it to a smaller format disc such as a DVD using Disk Utility. Otherwise you may need a burning utility such as Toast. This disk image shouldn't require Toast's blu-ray authoring plug-in.Note: Be sure that its enclosing folder's name doesn't contain any single quotes.
To prepare source from Toast generated disk image (in case you find you need to add something later) to so that it will be compatible with creating a new disk image:
Note: I've recently created a new Lion-compatible version, which is now also linked to this page as an attachment. The process seems to make a more compatible disk image (I don't get a kernel panic when I open the disk image in Finder anymore). It probably can't be used in its current form in Snow Leopard or Leopard, because of a specific change in the way AppleScript handles file writing in Lion workflows (the workflow script steps still contain commented syntax needed for the previous versions).