Thanks for the info guys. I checked my HS, it wasn't making full contact, slightly more than half of the CPU's imprint was on the bottom of the HS in ArctiSilverII. I took the CPU out and scraped it off with a clean credit card, then wiped the HS clean with a lens cloth. My HS is lapped and VERY smooth on the bottom (like a mirror). I had far less ASII on the CPU core than the ASII instructions showed. On their website you can't read the Intel numbers on the core, but with my original spread you could read through the ASII... now it is just a haze of ASII (barely). I can't see my CPU mating to the HS due to the retention bracket. But now I'm sure I have better contact as my temps dropped 5+ degrees C. At 1.6ghz I now get mid 40s (after only a few minutes of Prime95). Now I can boot at 133x16, but it won't load windows... though them temps never go over 52 now. I upped the voltage to 1.725 (as high as I will risk gents) and it still won't load Windows, I saw the deskto once

I'm now at 1.92ghz (1:1 ratio, AGP/PCI locked) and 1.650 volts core. It gives me error messages upon windows bootup... but Prine95 went 10 minutes without errors. I'm torture testing for an hour or so now. We'll see.
I still think I got the dud... but perhaps some of it is my fault (hard to make certain that HS is not tilted!). I hate taking the HS on and of and on and off... but I want to get it right!
I may try getting a better Enermax powersuppy too... perhaps my Antec 300 is the weak link (but voltages appear stable!)