handbrake experts, question on resolution

[sdinsmore]

i just got my d3 installed today (hoorah), ive got the 80gig video ipod hooked up thru the ipod interface. ive already ripped a bunch of movies, all with resolutions ranging from 480x234 to 312x234. If a movie was 2.35:1, then i would just crop the movie to the contrast ratio of the screen (480/234 = 2.05). So I now have a bunch of 480x234 movies which look GREAT on itunes and even on the ipod (in widescreen mode). HOWEVER, when i play these movies on the d3 they still have bars on them?! I tried every combonation of d3 screen modes (normal, full, zoom, etc) with both ipod modes (full, widescreen). No combonation filled up the screen perfectly without cutting out the sides & top/bottom. I could see the whole movie in one of the combonations, but there were bars on ALL sides... What gives?