ride525, I have a Samsung DLP HLN437W and I do not have this problem on mine with the 811 using DVI. Sometimes mine will 'freak out' on 1080i with some double imaging, but going to 720p then back to 1080i seems to fix it for me. I would try hooking up the components and see if that works better than the DVI for 1080i. I can tell you that your Sammy has a MUCH better scaler than the 811 and even though your Sammy's native is 720p, it will look MUCH better getting a 1080i signal from the 811 and scaling it itself. After you hook up the components, try some image adjustments, left then right from the HDTV menu. Turn it off and rehookup the DVI, that may take care of the problem. Cant hurt to try.
I agree that on my HLN507W Samsung DLP and 811, the PQ is much better on 1080i material when the 811 is set to 1080i and let the set scale it to 720p.
The only time 720p looks better in my setup is when the broadcast is in 720p.
Also, I get noticably better resolution on native HD program content with DVI over component.
I run 1080i DVI from my 811 to my DLP most of the time, and I have not seen the border problem that you describe. It sounds like overscan is not properly adjusted on the Sammy. You can adjust it from the service menu, and it's best to have a source like the AVIA disk or video essentials. There is detailed info on this in the AVS forum at http://avsforum.com.
ride525, I have a Samsung DLP HLN437W and I do not have this problem on mine with the 811 using DVI. Sometimes mine will 'freak out' on 1080i with some double imaging, but going to 720p then back to 1080i seems to fix it for me.
Sometimes mine "freaks out" and double images when I'm on OTA digital. But when I turn it back to a satellite channel, it goes back to a nice single picture. And I'm still on 720p, since the 1080i gave borders with my 811 and Samsung HLN 437.