Ok,
Installed CPUID last night and got some readings for power.
12V = 12.16 avg, 11.84 Min
Not graphed so cannot see if the min occured around the time of the hangs.
Other info gathered from 'out there'.....
Tech Harp
When you test the card out, be sure to note any visual abnormalities like corrupted textures. The game may even hang. This is a sign that one or more of the memory chips are failing at that clock speed. When that happens, clock down the memory bus by one step.
3D Guru
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So we fire off a hefty shader application at the GPU and start monitoring temperature behavior as it would mid-gaming, we literally stress the GPU 100% here. We measured at a set 21 degrees C room-temperature.
In idle you can expect a temperature of 45 degrees C / 113 F. Pretty normal. Yet once we push the GPU to 100%, the temperatures take a pretty hefty toll and settle at almost 70 Degrees C / 158F. This is also fine, actually pretty good for a pre-overclocked product.
My card was topping out around 79 deg but averaged around 65-68 deg
The PSU I have I believe is
this one (came with the case).
I took the machine apart completely last night to clean it out. There is only the exhaulst fan and the PSU fans for cooling the midi case. Both where pretty dusty with the exhaust fan choked to the point of sounding like a helicopter. I had to take out the motherboard to get the CPU fan out for cleaning and not everything is sparklie new. The PSU I believe is suffering from dust buildup as well but everytime I try and clean a PSU it tends to fail soon after

so I have left it alone apart from a vacumn.
Testing after all the cleaning resulted in no real differences in temps etc

although recovery time from a HL2 EP2 hang after jumping to desktop is more or less straight away.
Going on the notes above I may start underclocking the mem chips first and see if that fixes it. I am loath to accept a card which does not meet production specs especially as this card is meant to be overclockable on top of the factory overclock.
I will post a shot with the CPUID info tonight when I get home.
Cheers
RB