Hmm yeah that is an interesting route.
Is that different from what I did? Which was:
1) Bought this:
http://www.curtpalme.com/TC1500.shtm
2) Hooked up my TV to Mac Mini DVI and grabbed EDID info
3) Hooked up transcoder (1) and used DisplayConfigX to match the EDID info.
Unfortunately this didn't work right for some reason. I was able to get an image at times, but it was messed up. (wrong size, rounded corners, flickering pieces, etc) not synced
First let me say that I am fairly confident in my theory about what is happening in your situation. Normally when I am doing things like this it is a bigger convention/show situation with a video switcher/scaler involved. Units that cost a lot but will take anything you throw at it and change it to anything else. Take it with a grain of salt, but I think I know what the issue is.
Why does that converter not work?
Because it is changing the color space and I think some sync things, but not the resolution. For example the TC1500 faq says:
"Does the TC1500 change the resolution? Upconvert or downcovert?
The TC1500 does not change the resolution or refresh rate in any way. It simply converts a VGA (RGBHV) input signal to a component signal. The TC1500 outputs whatever resolution you feed it. Absolutely nothing is changed."
A similar device I found has the same fine print:
These units are not format converters. They pass the horizontal and vertical synchronization timings and pixel content to the outputs without modification.
So basically they solve only half the problem, color space. Resolution is still an issue.
I did find this. It has a fairly good explanation and some resolutions that work.
http://www.jwardell.com/info/minihtpc.html
Now you mentioned that sometimes you could get one TV to work but not others. Resolution issues is the reason. different TV's will have different "native" resolutions, based on the physical characteristics of the type of panel used. All HDTV's have to accept the HDTV spec resolutions. Basically HDTV's have very basic scalers that take a very limited number of resolutions. Usually just the spec ones and whatever the native panel is.
Example time:
All the TV's will accept spec 720p or 1080i
TVA will take 1366x768
TVB will take 1280x792
TVC-E will take "whatever"
If you had one HDTV, you could play with resolutions and find one that might not be to spec but close enough that the HDTV will display it. Trying to find a resolution they all "play nice with" probably isn't going to happen.
So I think it comes back around to the same issue of needing to get the mac to display the spec HDTV.
Another example:
My projector is hooked up DVI-HDMI to my mini. Display preferences knows that and gives 720p60 as an option because of the EDID. I don't know if the color space is RGB or YPbPr because that is a setting I can change on the projector. So it could be the mini that "knows" to output YPbPr, or the projector "knows" to convert the RGB to correctly. Also it is HDMI so there is probably other things going on.
Really long post but I think that Gefen device would solve your resolution issue. It may even solve the color space issue but even if it doesn't you already have the TC1500 that will.
Wow long post, sorry.