Hey, Lee,

If you haven't already done so, take a look in the advanced settings. I seem to remember there was something about pixel type or aspect ratio or something that affects the finished size. We had this problem some time ago, I can't remember exactly what we did to fix it, but I seem to remember it was something there.

Also, you might try just creating an entirely new setting and starting from scratch with all of your settings and see if that magically makes the problem go away. I've noticed that sometimes Sorenson will do some odd things for no apparent reason (might have to do with memory leaks in Windows) and doing that has fixed the weirdnesses more than once.

Hope that helps.