An update on some of the outstanding action items:
Testing w/only one LCD: I unplugged the second screen and reran the stability checks, my temps were unchanged (within a degree or two) and the rig locked per usual.
By "locked" I mean it sends the LCD into power-saving mode and then I am blind, can't get the screen to rewake unless I do a reboot.
A few things, IDC -
1) That sucks, sorry man XD.
2) That's a heck of an odd crash (full reboot) for it to be the graphics card's fault. Granted I haven't been on NVIDIA drives in a couple of years, but usually the should recover or BSOD at most if you're pushing the clocks too high. Have you tried other programs to stress test? How's gaming (if you're using the card for gaming)? How far can you push the card in games?
3) What PSU are you using and how much do you have plugged into it? Try unplugging non-essentials (extra HDD's, peripherals, the works) and re-running OCCT - see if it holds up with a lighter load on the rails.
4) Cooling doesn't look to be the problem at all. I'd say try more voltage with the 1.212V BIOS hack, but if the PSU is your problem then that could do more harm than good.
If it was me, I'd scrap OCCT GPU test and use actual programs/games to test for awhile. These synthetic programs/stress testers have their place, but I would never use just one program as an end-all (despite how awesome and easy that would be XD).
I thought I had good contact between the GPU and the cooler, my temps were around 60C and when I'd touch the fins of the GPU HSF they were definitely HOT.
But I went ahead and redid the TIM, using AS5 this time just to be sure.
I also reconfigured my case layout, the Black Pearl is one of the those cases that flips the mobo position so the bottom slots are actually positioned at the top of the case. I put my GPU in the top slot and the case fans in the top of the case push air into the intake fans on the GPU.
All else being the same, my loaded temps are now ~11C cooler. (running 49C vs 60C at stock overclock with OCCT)
Haven't tried OC'ing yet to see where my extra thermal budget takes me.
I did start
a thread in the PSU forum to find a new PSU to buy just on the chance that my PSU is dying on me, I bought it in Nov 2006.