Thanks for the additional information.
1:1 FW=544 else
Don't understand this one.
FWIW, you don't need to check every still image resolution with video recording. Recording effectively sets the aspect ratio to 16:9 or 4:3 depending on the video option.
Also, can you confirm the physical screen on this cam is 4:3, and if you choose 4:3 or VGA video, the image covers the whole screen?
Here's a new test build. If chdkptp sizes are OK, please check zebra too. Basically:
Aim at a bright light or something so the zebra shows some overexposure.
Move the aim around so the over exposed part moves to different parts of the screen, and make sure the zebra is on the right part of the image and not cut off.