I've decided to come at it all from a new angle: Windows XP

Prime95 seems to be the absolute choice in pushing your machines stability. So I gave it a go with my current bios settings. Low and behold it balked after about 10 minutes.

So back to bios I went - this time with an eye to overclock. So now I'm at 3.2 with a 400x8 multiplier and the ram at 800 vcore at 1.25 and memory at the same 5-5-5-15, 2.2v as before, also chnaged the nb to 1.4v. Ran Prime95 for 3 and half hours with no error and it didn't hit 60 degrees with my Zalman 9700. I'm back on leopard now to see how long it lasts without a KP.