Chunce: im not really sure why you cant get the screen to full size, does windows itself look chopped off? H. Size will make the screen bigger from left to right , I believe that is #31 on the remote, and V.Size will make it bigger up and down which is around 05 or 06 on the remote I believe. Just using those 2 alone should make the screen full size. Ill write down my color settings and post them and you can compare them with RubberPultry's color settings he posted above, but my screen settings are in a limbo at the moment from video card swapping.
I myself had 640x480 running perfectly but the screen flicker caused by the ATI to component dongle for 9x00 type cards was causing interlace flicker so now im trying to get a video card that does component without the dongle (nvidia 6/7 series, ATI x1k series) which has no flicker at all with component. I tried out a Geforce 7300GT yesterday with component and the screen was great looking however it would only come in as black and white, no matter what I tried I could not get a color picture on a SDTV, worked fine on a HDTV though, going to try out a ATI x1k next.
acevedor2: there is a lot of great TV's around but most have speakers on the side, which will instantly tell you it wont work in your cabinet, I know I would love to find a 27" HDTV without speakers on the side and in full-screen, or better yet a 27" fullscreen LCD.
Which video card are you guys using for output?