Replying to myself. I got this issue resolved by using a combination of CCC for crtemudrivers and the service menu on my tv and the arcadeosd modelines.
First tip is most important. I have found that the best setting is the vmmaker.ini file. use the custom modelines settings in there and find by trial and error or specs on your TV and enter these specifically. Generic will get you close with a TV and component transcoder. close enough to play the games. some games aka mk series and narc and some other will vertical scroll. since on a TV you have no pots and the service menu is digital its hard to get these "dialed" in. that's when grovvymame switchres and vmmaker.ini become critical. spend the time to get the vmmaker settings right. Here is my current setting on a transcoder and sony KV27fs120.
MonitorType = "CUSTOM"
monitor_specs0 15700-16200, 49.50-61.00, 4.100, 4.600, 8.700, 0.180, 0.180, .096, 0, 0, 288, 448
If you find BETTER settings than these feel free to chime in. The horizontal back porch settings were wrong on mine. that's where this thread originates. This moves the horizontal "pot" that you don't have on a TV. mine was set to 12 and I found 7 works the best on this TV for a centered image. However my modeline listed above does not reflect this. I had to manual adjust the H back porch on each resolution. It looked GREAT until I rebooted. So it seems even tho you save these settings in Arcadeosd....it does not really save them?
So all this time my settings that I change helped...but the service menu didn't move this enough. So a typical user may not even have to mess with the service menu. but that's where I started. im posting this info so you can start somewhere else and hopefully get it resolved.
What helped me on top of all this was installing catalyst control panel for xp64 9.3 because that's the calamity drivers im using. after getting the vertical size set using the service menu and vmmaker I was able to get everything satisfactory except two inches of blank on left hand side. with catalyst control I was able to move the entire desktop over two inches and save it. DO NOT TRY TO USE CCC TO MOVE VERTICAL OR IT WILL GO OUT OF SYNC.
so this issue appears resolved except for the fact im sure there is a VMMaker H back porch setting that I could use to not have to use CCC but I haven't figured that out yet.
H back porch 7ch 4.7 seems to work the best but its defaulting to 12.