Hi podge.I have recently upgraded to Sky HD & you will be interested to know the following:- I have been recording to the HD Box, Oliver Twist (x 5). When I copied them from the HD Box to my DVD Recorder I used the copy button for all 5 episodes & they all reproduced in Letterbox format (as you have mentioned). I then went further & played the 1st episode directly from the Sky Box to TV Screen. it showed in Letterbox, I then played a live programme from Sky & lo & behold it played in Letterbox Format,Every prog was the same.I removed the Sky Box from the wall socket & then re-placed it (thereby rebooting the Digibox) everything now back to normal. The conclusion I have reached(like you) is that the copy button on these boxes when used, re programmes the box to a different format every time & there is no way I can see to overcome this. Ron.