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It sounds like, for whatever reason, your burning program is not finalizing that last session. When it completes the disc, it will fill in that gap last thing. It can say 100% complete, but if that last session isn't finalized, it won't work.
I don't know what to tell you about correcting that. If I undertood you correctly, you said you no longer have the other CD? If all you've got is a CDI image, and you've tried everything with DJ, (burning in mode2, cd-xa, finalize/close disc, etc.), and you still get the same problem, then maybe you should try using Alcohol 120%. It burns DJ images as well. If you still have the disc, try using Nero or another program to copy it.
-Ex
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