Its simple really, BFG didnt test that card for those clocks, your card is probably better ioff with stock clocks, i would flash to the original BFG gtx 285 bios, im about 90% sure this will fix your problems, also BFG stating they wont do anymore RMA's is beyond stupid, they can get slapped with a nice lawsuit for that. They cannot deny your warranty, simple and plain, as long as the card is under warranty they cannot deny it, dont let them walk all over you as a customer, get some legal knowledge of the situation and take control, or else they will take advantage of you.