I know no one cares but I'm updating this thread anyway!
Even after disabling the 4th core on the i7 the CPU started blue-screening 5 days after the orignal post. It was dying a slow and painful death. I remembered people baking GPUs to bring them back to life, so I decided to give it a try. I let bake for 10mins @400F. IT WORKED!!!!
I let it prime95 for 24hrs yesterday and it passed. I'm not sure if I have a 1 week or a 1 year. Time will tell and I will update this thread when it dies. I'm sure someone, somewhere will find "Baking a CPU" useful.
EDIT: CPU was delidded and lapped. RMA wasn't an option.