Awesome. This is a kick ass project.
By the way, are you participating in the Sentey Mod Extreme 2011. You can surely win something in there.
PD: Tremendo laburo.
The answer were already given. If you are running at stock, then it's a deffective chip.
If you are OCing it, then that's the problem. Try to lower the clock, or the multiplier, or boths. Or add some voltage.