[Patrics83]

Found the issue!

It's because of my overscan settings.

Code:

#  1080p
  overscan_left=39
  overscan_right=39
  overscan_top=23
  overscan_bottom=24

Shouldn't I be able to use this anymore? I thought this method was better to use instead of the videocalibration tool inside kodi.

Actually I think you'll find "overscan_scale=1" is the critical setting.
Without overscan_scale, the other overscan settings will have no effect to kodi.

But, no. You should not be using any overscan settings in config.txt with kodi.

For best quality fix the problem on the TV. Check the display menu options and disable overscan (it may be called "just scan", "screen fit", "HD size", "full pixel", "unscaled", "dot by dot", "native" or "1:1").
If you can't do that then use the kodi calibration settings. That will result in a resize by the TV which will make the image less sharp.
Using overscan_scale will result in a resize by the Pi, followed by a resize by the TV resulting in an even less sharp image.

I'll try to discover why the overscan_scale stopped working.

Oh yeah I know about this and normally I'm using it. But for some reason I had to do this workaround in the past to make all my connected stuff work without problem. (I have a receiver with only one hdmi to the tv)
Back in the past when I calibrated through xbmc the video menu was cut off if I remember right.

Edit: FYI you said that overscan settings didn't work. They actually worked because my screen was the same as before just that things went crazy during/after a movie was played.

Thanks for explaining!

Are you sure it was #0430 that was the first broken build?
There were no related changes there. #0501 did have some firmware related display changes so seems more likely.

Yes I'm 100% sure. With that config.txt I had before the issue was reproducible when jumping between #0429 and #0430

This is exactly how I found the first build.
#0105 =good > #0202 =good > #0401 =good > #0501 =bad > #0430 =bad > #0429 =good