Encore SD Project Changes size after DVD Burn?

Okay I've never had any issues with Encore CS5.5, but most of my experience is with HD video so I could be missing something simple...
I built a Premiere Pro project and Adobe Dynamic Link'ed it over to Encore, created the menus etc and everything is great. Check Project finds no issues, it Previews perfectly and looks like this:
(screenshot taken directly from the Encore 'Preview' window)
Once on the DVD, I place the DVD into a DVD player and it comes out like this:
(Picture of DVD loaded in DVD Player/TV, where for some reason it has cut down all sides)
I tested it with multiple TV's and DVD players, changes aspect ratios, doubles checked that both Premiere and Encore files are correct sizes....... Having not worked with SD videos in Encore before... is there something simple I'm missing? I have the client waiting for the DVD, but I'm completely at a loss.
The footage is 720x480, 29.97fps

Alright, I tried double and triple checking the project settings and burned the DVD again, with the same results. Here are the project settings:
I'm at a total loss.
I will now try what John recommended, though I don't see how that will change because the menu I used I COPIED directly from the stock encore menu library, edited in photoshop and saved back into the Encore library under a different name (as I've always done with ALL previous HD menu's with perfect results. The ONLY difference here being it's SD instead of HD) and the whole project comes out cropped on all four sides.... so I see no way that it could be an issue on the Premiere side of things.
I'll still try it though because I'm completely at a loss......

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