After reading many many different articles and posts I finally got around to OC'ing my E8400 to the 4Ghz level.
CPU:
E8400: E0
Mobo:
DFI Lanparty DK X38
Ram:
GSkill 4GB DDR2 1066
Heatsink:
Xigmatek HDT-S1283 w/ 120mm fan
I got the E8400 back in December and took it to 3.6Ghz by simply increasing the FSB to 400. It was the easiest OC I've ever done and the core temps stayed under 40C even at full load (Idle at 30-33C, room temp around 21-24C). Also, I made sure my Ram was runing at 5-5-5-15 in the BIOS. Six months ago I tried to take it to 4.0Ghz but it kept crashing on me and I didn't feel like messing around with the voltages to get it to work.
Until yesterday that is. I finally got off my butt and decided to take it the rest of the way to 4Ghz. I'm ashamed at how easy it was to OC this E8400 to the 4.0Ghz plateau. If I had spent another 10 min back in December, I could have been running at 4.0Ghz for the last 6 months. But anyway, it's running rock solid now:
4.0Ghz
445 FSB
1.265 Vcore (up from default 1.25V)
2.0V DRAM (up from default 1.9v)
All other voltages at stock (NB, SB, VTT remain at BIOS default. Didn't have to adjust these to make the system stable)
Temps: Idles at 30-33C (same as for the 3.6Ghz OC). Prime 95 test (full load) sends the temps to the 40-42C range... not bad at all. Nearly identical temps as the 3.6Ghz OC, just a degree or two higher at full load. Room temp is normal (21-24C, or 71-75F).
CPU-Z reports ram running at 5:6 ratio (at 533Mhz), not sure how I can get that to 1:1 or 1:2, or if it even matters. I'm at work, so I can't do any more testing right now, and my voltage numbers may be a little off, but I'll fix that once I get home and post a pic of CPU-Z up for future reference.
Also, I wasn't sure how much extra voltage I would need to get to 4Ghz, so I initially just started at 1.36V and kept reducing it until it wasn't stable anymore. The final stable voltage is just 3 notches above the default 1.25V in my DFI bios. Full load temps at 1.36V were in the 53-54C range, FYI, which is still safe. I could probably take the chip to 4.2Ghz or 4.3Ghz I'm guessing, but I don't feel the need to stress my chip like that.
So yeah, getting an E8400 to 4.0Ghz was very painless for me and I consider myself lucky! Posting here to help out anyone searching in the future.