Yah, I seriously just lucked the hell out

. This card is just unbelievable. I played FEAR for easily 45 minutes with absolutely NO glitches at 460/1250. Anyway, better cooling is definitely in order, as I still am not comfortable with 100C load temps.
And yes, the faster you run the chip the hotter it will get. The ability of the chip to run speeds in excess of specifications is based upon many factors, including quality of the silicon, where the chip was on the wafer, the other components in the card, etc. etc. None of these are really able to be determined pre-operation and are characteristic of each individual card, so overclocking ability is for the most part luck, although there are a few tricks to get a little more juice out of your card (such as cooling :thumbup).
Btw, overvolting doesn't really seem to work through BIOS flashing (at least for my original card) and it is very dangerous on such a specific operating environment, so I wouldn't recommend it.
If you're looking for sheet metal, I think 28 guage (0.0135") would work best on these new heatsinks
