ok, so I contacted B&H and they replaced my projector with a new one, almost no questions asked. I sent them the pic i posted earlier and they issued an RMA immediately. So I got the new projector in and the convergence is MUCH better, but not perfect. its only maybe two or three pixels off. I can live with that. BUT I have a new issue. I seems like anything from a streaming source sutters on playback. it'll play maybe 30 seconds perfectly fine, then it'll stutter like slow motion for 5-10 seconds and then it catches back up. repeat.
It doesn't happen with cable, it doesn't happen with blu-ray. It stutters with streaming content on roku 2, roku 3, and xbox 360. games do not stutter. these same sources do not stutter on my Panasonic plasma, and I'm on 50/25 fios, so its not the internet. I've tried different cables, if its some kind of HDCP issue I've tried routing through a receiver, a splitter, a switch, and directly to the projector, same problem. strangely, an old roku HDX doesn't stutter at all. the biggest stutterer is VUDU, but it does it equally at any quality setting.
anyone have any ideas on what else to try? I'm about ready to throw it out and just get a ZT.