To fix the wdith problem, I think Vic hit the nail on the head. You can shrink the image width up to a certain point using the convergance pots, but the prefered way to make the adjustment is using the width coils. On the 1020 the coils are located in the upper left (looking at the PJ from the back) on the E board. There are three of them, one for each color, and they kind of look like three little spools of thread sitting on the board. They are adjusted by a hex screw in the center, that can be turned with an adjustment tool such as that in Radio Shack kit #64-2230. Mine were not very sensitive, and required several complete turns to correctly set the width.
Here is the method I used (pieced together from info here on the board) to correctly set my height and width for 16:9 projection. Again I highly recommend going 16:9 with these video only units to reduce scan lines, you just have to set your DVD player to widescreen TV, and be playing anamorphic or enhanced widesceen DVDs. This may not work verbatim for your setup, but its a starting place.
1. Using masking tape, measure out and mask off the 16:9 screen size you are shooting for on the wall using the calculations in the manual.
2. Turn off Red and Blue tubes.
3. project the crosshatch test pattern (or preferably play one from the DVD player)
4. center all convergance pots
5. set the green v-size pot about half way between center and its smallest setting, and master h-size pot about half way between center and its biggest setting making sure that the image on the face of the green tube does not extend beyond the edges of the of the tube face.
6. move the projector back and forth (adjusting green center focus as you go) until the height of the projected cross hatch just overlaps the top and bottom of the masked screen area.
7. adjust the green width coil to set the width to where it just overlaps the sides of the screen area, again being very careful that the image on the tube face does not extend off the edges of the tube face.
8. turn on red, focus the center.
9. use the red v-size pot to roughly match the height of the red crosshatch to the green.
10. use the red width coil to roughly match the red width to the green.
11. repeat 8, 9 and 10 for the blue tube.
12. go back and fine tune the center and edge focus on each tube and then go ahead and do a full convergance.
The only thing this method doesn't do is guarantee that you are maximizing your horizontal raster usage. Ideally you would set the width by looking at the tube face and pushing the raster out to 1/4" or so from the tube edges, then adjust the PJ distance to screen so that the width fits the screen. The problem is that you then may not have enough v-size adjustment to be able to get to both 16:9 and 4:3 which then leads to considerably more involved adjustments. If it were to turn out that you did have enough adjustment on v-size, then chances are the method above would have ended up using most of the horizontal phosphor anyways.
Now when you want to view 4:3 material such as non-animorphic DVDs or regular TV, you have 2 choices. you can pop the top and just shrink the master h-size until you are back to 4:3, or you can increase the G, R and B v-size to get you to 4:3. If you increase the v-size, again be very careful that the image does not extend outside the face of the tube.
Going to 4:3 by shrinking the main h-size will result in a smaller, nicer image particularly for lower resolution sources such as regular tv and vhs. However there is a disadvantage, particularly if you watch a lot of material in this mode, that you are using a very small amount of phosphor in the center of the tube. This will eventually cause a small 4:3 wear pattern that will be visable when you go out to 16:9. For this reason, I take the option of growing the v-sizes for watching 4:3 material. It is definately a worse image, but much of that can be made up for by sitting farther back from the screen. Another nice benefit is that most static images in 4:3 material such as controls in video games, or TV station id logos will tend to be above or below the main 16:9 area, so if they do cause burn in, it will not be visable in your movies.
Good Luck,
Rob