If you link to the photo on HKEPC you will notice that they don't actually have the two chips next to each other, but next to a coin to give some frame of size reference. So, that means that Xbit has a picture of R520 from one source and a picture of R480 from another, and then they pasted them together to make a size comparison. The mistake here is that they are assuming that the entire chip itself itself is the exact same size as R480. I'm not saying that their conslusion is incorrect... The R520 core may well be smaller than than R480, but their methods are certainly less than scientific.
Edit: Additionally, just because someone has a physical sample, doesn't mean anything about production. It wasn't that long ago, before the 7800GTX was launched that we are all looking at an engineering sample G70 based card that was so fried that it had burn marks on it. Of course, we couldn't see them in the pictures until they were pointed out to us by someone who had seen the card in person. Obvioulsy, that didn't stop the launch of the GTX, but I wouldn't put too much stock into leaked, cropped, and blurry photos you see on the web.