Turns out it wasn't the size that caused the non-creation of the BIN files. Something got corrupt in the packer folder. I reinstalled it and it made the BIN files. Of course, I have a new issues now. Some new songs I made aren't showing up and some of my old songs aren't either even after I refreshed the cache so something is wrong somewhere and I gotta figure it out.
This may be the start of some very complicated errors. But of course, it can be caused by a number of things. First, are you sure you're refreshing the cache with a blank one? If you're accidentally reloading with a used cache, it won't read the same song again. Similarly, if a song appears twice in a DTA, it won't get read at all, so make sure all the songs.dta files reference all the correct songs. You are aware of file size limits, but watch for those too. Make sure you're not overwriting app files by having folders pack to the same number as another folder. Make sure your packdlc.bat is referencing correct folder names.
Any progress on this?
Weird. I need to check my files over again to see if anything has changed that I overlooked.
I don't know what it could be. It became more difficult to manage virtual NANDs on Dolphin past version 4.0, so I can't exactly pull apart my working files to see what made it work, and yet I also can't just as simply start from scratch to see what the minimum requirements are. What I found, though, was that my SYSCONF file is slightly different from the one available now, so I guess you could try that and see how it goes.http://ge.tt/7t1LFMK1/v/0?c
Otherwise, start putting .app files at Sys\Wii\title\00010005\735a4145\content with its correct TMD file. The loading bar appearing at all should be dependent on the ticket file.