I would like to avoid having to recreate over a hundred chapter points and a large number of menus with animated backgrounds. If I can achieve this by fooling Encore into relinking to .mov's of a different resolution then I'll be a happy person.
I would try a bit more at getting the encore "make a DVD from a BD project" workflow to work. Many users have issues.
Yes, your encode settings may be the issue. What are they?
The whole BD to DVD may be unrelated to the aspect ratio error. I would try that workflow first with a simpler project with your actual assets. Build the BD (as you have already done). One timeline and asset with chapters. One menu with background video. Does it work as BD? Now change the project settings, and pay attention to the DVD default transcode (there aren't many choices). Use "transcode now" rather than letting the timeline transcodes happen at build.
