Okay, more info. I went back and reinstalled the last 1.99.xx I had, and re-encoded some content I still had. 1.99 gave me the perfect aspect ratio, full picture width in a 16:9 ratio with small black bars at the top and bottom. Subs still don't appear though.
I went back and checked some of the other stuff I'd done with 2.04, and it looks terrible in comparison, with about 12 percent of the picture cropped off the left and the right of what should be widescreen, and then expanded to fill the widescreen format, causing lots of artifacts and a distorted picture. I checked some TV shows and they looked even worse - as bad as VCD done with Nerovision, with even bigger (relative to the content) crops on the left and right. I can fiddle with my TV's aspect ratio to get something semi-watchable, but I lose content from all edges by blowing up the picture to the middle only. I didn't buy a widescreen TV in order to expand wide-screen content.
I don't know what more to say really. 2.04 just produces fine results on my PC, but is absolutely atrocious on my standalone, whereas
DivxtoDVD 1.99 is great. Given that the whole point of ConvertX is to produce a playable, compatible disc for your standalone player, 2.04 has some major bugs that ruin the picture quality, crop out content, and get the aspect ratio wrong.
It would be really nice to have a VSO rep acknowledge the problem (this is after all listed at the VSO site as a VSO support forum) and give me some hope that there will be a fix in the future.