lhamp,
If you noticed my post from yesterday "VGA Problem with Sony?", I mentioned, on my Zenith, that non-hd stations were horizontally squished about 20%. This was EXACTLY the same problem I had with the RCA before they downloaded the additional retrace timings several months ago. I didn't notice a problem with the component picture which seems properly sized or with the 1080i signals through the VGA connector. I have a feeling this could be part of your problem (retrace timings). Someone else noted a similair problem in a post several days ago.
I alerted Sony to this problem, but in the meantime, if you can go through component output (if your setup allows), this may be the fix. This assumes that you have set the Sony to 16:9.