Can't quite understand why you're having a problem with this. In my setup my second output on the graphics card goes to my Onkyo receiver via a DVI-HDMI cable with a resolution of 1280x720 at 59Hz. The receiver outputs everything on it's HDMI connection to the projector - again at 1280x720.
I'm afraid I don't have any other suggestions for your problem...but I if you're getting a good picture on your projector from HD TV sources I doubt the problem is at the projector side of things.
There's no need to use RS232 to control the projector.
RG