Thanks to Reaper, Gary, Red5908, and Mark for the feedback. I had started re-rendering last night. I had selected the NTSC button in blender and went with whatever it changed to which was X=720, Y=480, AspX=10, AspY=11. (this was before reading the last post from Mark which I still want to try with the different Asp settings) Anyway it rendered in about 17 hours and works perfectly. It plays in MediaPlayer and my burning software although a bit "jerky" in mediapayer. Googled the audio and got an mp3 for sound which edited in perfectly. Still hope to try the ac3 someday.
Burning went smooth. Just played successfully on my big screen
and as Reaper had said earlier in the thread the PJ just stretched it through HDMI and fit it to screen. Looks great and actually sounds good with just the mp3 sound file which the burning software converted to an ac3 file so it does play out of all speakers.
Thanks Reaper for the patience, feedback and follow up. It looks GREAT ! and really makes the theater feel special. My wife and son loved it and it is especially cool because you don't realize it right away until the camera swings around to reveal the custom coolness.