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Sorry, I didn't clearly call out that I wiped my drive and put down the fresh 2.8 image when you asked the other day. 

All I've done after that was change 2 player to 4 player and the highres.txt. 

That's what I thought....

I don't understand how this is happening, I'm going to have to think about it and get back to you a bit later.  The only resolutions available in highres mode should be 480p.... need to figure out where it's going wrong.

EDIT: are you plugged into HDMI-0 or HDMI-1?  You want to be using HDMI-0 (the one nearest the SD card).... HDMI-1 is not configured.  That's all I've come up with so far...

In the meantime, can I manually force 480p?  Or can we save the MAME stretch settings as a workaround? It would be great to be able to use it while we figure it out. 

You'd need to edit the launcher scripts to do it that way.

Check your HDMI connection to the Pi, it's the only way I have been able to replicate your results.  You should be plugged into the one closest to the SD card, the other one is not setup.  Not sure if you saw my edit to the previous post.  I'm pretty sure this must be the issue.

Sorry I missed your edit.

I tried both micro HDMI ports and both go to the same 1280x1024 resolution.  I thought about mentioning that I'm using the Raspberry Pi 5 4GB version.  It doesn't have an SD card so I boot from USB.  https://www.pishop.us/product/raspberry-pi-5-4gb/?src=raspberrypi

Please check your cmdline.txt file (in the boot partition), it should be:

console=serial0,115200 console=tty3 root=PARTUUID=06e46955-02 rootfstype=ext4 elevator=deadline fsck.mode=skip rootwait logo.nologo plymouth.nolog loglevel=3 rd.udev.log_priority=3 vt.global_cursor_default=0 video=HDMI-A-1:640x480M@60 quiet splash plymouth.ignore-serial-consoles

That's one of 2 things that should have the Pi5 running at 480p.

For the second try this little update: https://mega.nz/file/N99j3ZBb#C6pgcceUObXcGu588kE9y-HcIzmanEI_Wv1Gug1oLKY
put the contents of the zip in the config-updater folder and run the update from the service menu (f4 or service button from the game selection menu to open ARpiCADEs service menu). - I have no way to test this so currently, it's just a theory...

Unless there's been another change to the Pi5s yours should work fine, I have 2,4 and 8 gig models.  Sometimes there are minor hardware revisions that require updates but as everything seems pretty normal except the resolution I don't think it's that in this case. 

I haven't ran ARpiCADE off a USB before, I wouldn't think that's making a difference though, if you have an SD card lying around to try you could rule it out.  Otherwise I may have to run some tests on a USB stick...

Hopefully the 2 things I've suggested here will fix it for you one way or another.

My cmdline.txt contents are:

console=serial0,115200 console=tty3 root=PARTUUID=06e46955-02 rootfstype=ext4 elevator=deadline fsck.mode=skip rootwait logo.nologo plymouth.nolog loglevel=3 rd.udev.log_priority=3 vt.global_cursor_default=0 video=HDMI-A-1:640x480M@60,margin_left=30,margin_right=80,margin_top=0,margin_bottom=0 quiet splash plymouth.ignore-serial-consoles

Unfortunately the same result after the update.  Tried both micro HDMI.   

I've wondered if it could be my monitor but it displays the launch menu fine.  And it displays when I use MAME stretch, so I don't think it's that. 

Sorry man haven't forgotten you, there's been some things come uip in my family this week.  I've got an idea to test that should hopefully at least fix the MAME scaling for you.  Still not actually sure why your system is stuck in 1024p though.

I'm back!

@DR88 please try this version of the 279 launcher script.  I've added 1024p to the highres handling.  Just unzip this and put the mame279.sh script into the launchers folder, it should be fine to just overwrite the existing one the only change is adding 1024p handling for MAME 0.279 it won't change the res or anything.
https://mega.nz/file/x9MCUBDY#EDGDyGjMQPnBJpYOivsZx_kgOmZ8M-EVbdLgqm124gk

I tested it using the second HDMI output, hopefully it also works for you.  I still recommend using HDMI-0 but it was convenient for me to test that way.

I'd love to know why your system isn't using 480p too but at least this should get you going.

Just wanted to let you know I'm out of town until Sunday.  Will check it out then.  Thank you for the support!

That seems to work for me.  Didn't get to play, but it booted the game up in the correct proportions. 

Please let me know if there's any other testing you want me to do.  I appreciate your support.