Well, here's what I did with my Replay 4160 and Hughes HTL-HD before I got the HD Tivo (I still do this for stuff I want to save to DVD):
I feed the HTL-HD simultaneous 480i output to the Replay's S-video input.
I have a Replay channel set up for LOST on Wednesday night, starting 5 minutes early (6:55PM for me here in the Central time zone).
I have a weekly timer set up on the HTL-HD itself to turn to 30-1 (the ABC station here) at 6:59PM.
The Replay not only records LOST in stunning 16x9 (it's the best looking show on HDTV other than live sports), but retains the description in the Replay Guide as well!
Here's where things REALLY get good...
I then use WinReplayPC or DVArchive to transfer the show to my PC. It plays on the PC as a 4x3 mpeg where everyone is tall and skinny. This is good, we take care of it later.
I use Womble to cut out the commercials. The edited file is still 4x3 with everyone tall and skinny.
I use DVD Patcher (
http://www.videohelp.com/download/DVDPatcher_v106.zip ) to change just the HEADERS of the edited file from 4x3 to 16x9. I leave the bitrate and resolution the way they are, and tell it to patch the entire file. Now I have a 16x9, 720x480, 6000kbps mpeg file.
I import that new 16x9 mpeg file into TMPGEnc DVD Author (actually I do two episodes per disc), and author and burn.
Result: Fantastic looking, not just 4x3 letterboxed, but genuine 16x9 DVD's.