Well I can answer #2 I think. Can't you just burn some of the episodes to one DVD and some to another? I don't see any other way around it. DVD's only go up to 4.7GB of storage. Program wise I use Roxio - its not free but you can probably snag a trial of it. Check out this one thread - its full of freebies Lots and Lots of FREE Software

As for question #1 that you would need to talk to STaRDoGG about. Because the site is so new were still kinda upside down on the cost of things.

What are you converting them from, and to? Are you converting to Divx/Xvid? That's probably the best compression you'll be able to get a video down to size with.

Are you trying to make menu's? Or just throw them all as single episodes onto a dvd until it's full?

The best you can really do is get DivX pro and play around with the compression settions and quality to find an acceptable medium of quality loss vs. size. The smaller it is, the worse it'll look, but you'll be able to fit more on a dvd. Divx Pro isn't free though, but there is a free version with less features. And you can use Virtualdub to do the editing and compressing.

You'll most likely just have to just use 2 DVD's. If you don't mind spanning the episodes across multiple DVD's, you can put less episodes on each DVD (about 6) and add your own cool menu's that you can use in a DVD player (or on your computer with DVD software like WinDVD or PowerDVD). One nice (non freeware) app to easily do that is called Convertxtodvd and here's a little guide on how to do it:

About Premium Membership, there will be a way to earn free premium but I haven't planned it all out yet. One will be a certain number of Drops earned, submitting working codes, maybe writing a certain number of quality tutorials, and whatever else I can think of. I should figure it all out fairly soon.