Don't put brasso on it. It attacks the surface, you don't want that.
800 will be fine, you're aiming at flat, not at shiny. Shiny is nice but not as important as flat
You might be able to make a case for rmaing it, but it'll be tricky to explain why you're so worried about a couple of degrees without admitting your overclocking the chip, which I think they'll frown on. Do let us know how it goes if you try it
Did I read that right? Lapping does not prevent you rma'ing the processor to intel?
once you admit O/C your CPU intel will refuse an RMA ive tried it before!! if you lap it then you have no warrenty!
lap the heatsink.
You sure it's now only contacting at the edges? When you take it off, this would look like a large amount of paste in the middle and not much around the edge. A photo would be good here.