I would say the route you are thinking of is the best. Yes, it will take a lot of work in the Imagepro, but often times, to get the best, you need to do more setup....

The only other options would be to actually set up the output resolution of catalyst to your desired resolution, which computers dont seem to like very often. Or, you could try running HD-SDI which would give you more resolution. Or, instead of going SDI, do a DVI over Cat5 or Fiber solution, and then just set your raster in the LED wall's processors accordingly. I think this is really one of the only ways to stay truly pixel-accurate. This is why I more often that not decide to have my servers live next to the image processors for the various devices, so I can easily stay DVI the whole way, then network the servers, and run an ethernet line to FOH, hook it up to my laptop, and use that for remote management.

Jason Rudolph