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I just discovered that the message you mention also appears sometimes when there is a valid IP.BIN in the file. There is a bug in the older version of BIN2BOOT (which I got from DCCOPYWORLD but is no longer there).
I downloaded a new copy from http://dcxeal.virtualave.net/b2b-cdda-b1.zip
This is apparently the latest version and it works on .BIN or .ISO files that the older version didn't. I just played around with creating a CRAZYTAXI.ISO file from the files on my game disc, then I used the older BIN2BOOT that I already had and got the same error. I used the new one I just downloaded and it worked. I burned a copy to a CDRW (I didn't test it on my DC, but I examined the file and disc structures).
I used the new BIN2BOOT on MrDriller (KAL-MRDR.BIN) and made a bootable disc that resembled in structure, the one I made of CrazyTaxi. I tested it successfully in my DC.
Mind you, my Dreamcast is the older variety, but I can vouch for the fact that this utility doesn't use a blank audio session before the data. It actually appears to burn the data to the first session and then burns an empty second session - only importing the directory from the first one. The results is that you have two sessions with the same files, although the second session is exactly 600KB in size.
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