Well that put my mind at ease just a bit.
How was that other cooler design different? Was it something you could really see and recognize?
My 6800U cooler looks about the same, but perhaps they made the later (7800GTX) coolers cheaper and therefor less efficient in some way.
I still my try it.
With pulling the shim off the GPU I guess you don't mean your own on-top-of-the-core shim, but the little ring on the outside.
I'm not sure I'd want to do that, crushing cores seems to be something that does happen now and then, but heat having to pass through 3 layers of material before it gets to the heat pipe assembly doesn't exactly help either... Tell me how it goes

If you want to reduce the 7800's heat, even temporarily, you may want to try a simpler and safer approach than reflashing all the time.
Just lower the max multiplier on your CPU with f.i. RMclock!
It wil reduce CPU temps and that will leave more cooling capacity from the air coming off the CPU sink for the GPU sink.
If you lower the multiplier enough you will also get the added effect that the 7800GTX will not have enough CPU time to do it's thing at full speed thereby also creating less heat.
This way you will have at the same heat as with reflashing, a little higher performance.
EDIT:
As far as your taking off the shim, I think I'll beat you to that with a slightly less invasive procedure.
I just take my ol' faithfull Dremel and shave about the same height off of the shim as the core is lower than the shim + a little extra.
This should give me perfect and tight contact without the use of the on-core shim and two layers of greasey crap.
I noted the 6800U's core is not hindered bya shim... so I can't practive on my garbage 6800U.
(cool huh, my 6800U has been degraded to garbage when people here would pay money for it if I just wouldn't kill it

)
And while I'm at it: I posted a couple of days ago a site that sold the GPU fans, but they're sold out and have no idea when they'll have it again.
I'm planning a software switching increased fan power mod, but I need an extra fan to try it on!
Anybody can help me out? In any way? (f.e. I can't order it with Dell, europe, they're even bigger asswipes than in the US)
EDIT2:
I meant the peltier cooled lappie cooler, not an internal pletier...