Ok more info and lets see if we can crush this....
CLEAN Install - Just Formatted. Vista 32 Bit (SP1 ONLY) No other updates done.
No Anti Virus, Firewall off and VMC has not been run yet
Latest nvidia, nforce and realtek HD Audio drivers.
Projector (Optima EP719) is Native 1024x768 so left it at that.
Total Theater 3 Plat. Updated to 3.x.140
Hardware Accel Off.
No Errors in Log except for "Unexpected Shutdown"
Seem to be making "Some" headway as movies only seem to freeze 1-2 times thoughout play. Basically Freeze then restart pickup where I left off.
Also Updated the Bios on the MB.
Don't know what else to try. I could pickup a different video card but other then that I really have no idea what else to try.