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I also need to recheck what happens on my 4:3 set. I would expect smaller letterbox bars on 1.66:1 material. However, this set does an automatic squeeze which I thought was a fixed squeeze of the raster at the 1.78:1 ratio or thereabouts. For 2.35:1 materials the player adds extra black bars.
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If your set is like mine (sony 4x3 RPTV with "squeeze" mode), then what you're describing is almost 100% correct. You'd expect to see the pillar box bars on that set as well. The only thing you're a little off on is teh 2.35:1 material. In that case, the player isn't adding anything. Those black bars are recorded on the DVD. They are the matting necessary to show a 2.35:1 picture inside of a 1.85:1 frame. Just a minor technicality, but I thought I'd point it out.
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But for 1.66:1, should I not see again pillarbox bars (small ones) as the image is slotted-into the 1.78:1 window? Maybe overscan again is causing the cropping.
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Yes, you'd expect to. You're probably right that the over scan is again preventing you from seeing them. I just put in my copy of The Lion King and watched a few minutes. There are no pillar boxing bars visible on my screen. I got very close to make sure.
I then put in Digital Video Essentials and showed the 1.33:1 overscan pattern. Both in "regular" 1.33:1 mode and in 1.85:1 "squeeze" mode my set is right at 5% on all sides, with the left and bottom sides even further off so the 5% line disappears. I guess that's why I don't see the pillars. I'd expect you to get similar results on both of your sets.
That was fun.
Brian.