1) If you set the borders right (which might take some tweaking) they shouldn't be visible.
It's indeed a trial-and-error process, and if your DVD player supports it I suggest using RW discs.
Note that if you play the DVD on your PC, the borders will be VERY visible...
but there's no way around that.
2) I said "afaik" in the comment, but actually I've been using anamorphic encoding
for all 16:9 for quite a while. These play fine on my widescreen TV, though I do have to
manually set the TV in the right mode.
Note that DVD has a resolution of only 720x480 or something like that btw, so while you
could encode 1280x720 anime to DVD, you'll be downsizing it. Of course, it'll be a while before
I'll put out a HD-DVD or Bly Ray DVD version of my guide
