So the new temps with the redremeled base and sflex fans are much better?

Where did you buy you sflexes from? They are discontinued. Wonder what the replacement fans are called.

Don't they have any coolers that fit without mods?

Yes the Accelero Extreme 7970, but it is too long. It is also much heavier and more expensive.

Is it necessary to use 2 x 120mm 800rpm fans for cooling? Do you think you could get away with one if you don't overclock too much?

One way to check whether the parts mated together well would be to put several layers of duct tape in the middle of the HSF in the same dimensions as the GPU die. That way you could see how well it lined up before dremeling.

JazzJackRabbit: Did you take any photos of the heatsink dremel modication?

I want to buy a HD7950 this weekend and am also thinking of ordering the same accelero heatsink cooler.

Im guessing the copper is quite easy to work with as its a soft metal.