Most unstable computer in 15 years: H55 and Clarkdale

I just put together a new HTPC built around the H55 and Intel 661 processor. This is the most unstable computer I have ever built in over 15 years. I can't even remember a time when I have seen any computer that has more problems than this one. I have spent every weekend for 2 months now trying different setups/configurations to get this thing stable. When I see this level of instability, it can usually be traced back to the memory but I have run this memory through memtest86 for 24 hours straight with no errors. This computer will blue screen just sitting there doing nothing (at least nothing that is user caused). My problems always seem to be related to the Windows Desktop Manager or Media Center. Make sense since this is an HTPC.

Every time I test a new config I start with a new vanilla install of Windows 7. While Win 7 32bit seems to run smoother, it also tends to crash more. Win 7 64bit gives me issues with recording TV and also tends to crash a lot. I've tried fail safe BIOS settings and Optimized BIOS settings. The only thing that I can say for sure is that the HPET setting in the BIOS definately causes the system to crash...usually on boot up.

I can't nail this down to the board, the processor, or the memory. My wife calls me every single week with a new problem with the computer. Since it's attached to the main TV, this is a huge problem for me. Has anyone else been having a hard time getting this type of setup stable?

Here are some standard things I setup with my hardware:

Win 7 32 or 64 bit
4GB RAM
Intel 661
Gigabyte GA-H55M-S2H (F5)
2TB drive
2x Avermedia USB hybrid tuners

Software:
Media Browser
Arcsoft TMT3 1.70
Virtual Clone Drive

Drivers:
Intel HD Graphics v 2086
Intel Chipset software v 1025
Intel MEI v1215
Intel Rapid Storage v1014

-I have tested a vanilla install with just the Intel MEI and Graphics drivers only installed. I have also tested every combination of each driver. I have tested the last 2 or 3 versions of each driver. I have tested the base drivers that ship with the board. In every case, crashes. There appears to be no combination of drivers that make this setup more stable.

I had the exact same software setup on my last i7 920 HTPC. It was rock solid. I am at my wits end.

I guess it's possible to have a faulty PSU but definately not underpowered. I keep the machine running on power saver mode and all my BIOS settings are geared towards power saving vs. performance. This CPU runs around 5W of power while using media center. It is constantly blowing cold air from the case because it runs so cool.

Here is the hardware I have:
1 BD drive
1 2TB hard drive
2x 2GB DDR3 RAM
1 Intel 661 CPU
2x Avermedia USB tuners
1 MicroFusion Remote 350 (350W PSU)

I run the Power Supply Calc here and even under 100% load the PSU requirements are around 180W...almost 1/2 of the max of the PSU. Also, if it was PSU related, I would think it would crash when I did something that was a bit more intensive. For instance, I got a BSOD last night by right clicking on an item in my start menu. Sometimes it will just BSOD while idle. Sometimes it is while recording. There isn't anything consistent.

The event viewer usually states that DWM.exe or ehshell.exe crashed. I've been running with the Windows Desktop Manager disabled. This seems to help but is something I SHOULDN'T HAVE to do. Every other machine I have/use that runs Windows 7 runs with DWM no problem. This is on top of all the other issues I have with this setup. If interested you can read them here.

I have seen other posts about problems with 4GB of RAM being a problem. My experience has shown that irregular behavior is usually tied to bad memory. I haven't tested with just one stick but that may be a good idea to test with.

One HUGE problem is that this thing runs my main TV and I travel during the week. My wife/kids would kill me if I didn't leave them a TV to use for a week at a time. I have to test stuff around their schedule and on weekends only so that limits what I am able to do.

I have and use the Ultimate Boot disk with all the motherboard/cpu/memory/hard drive testing apps on it. I've run the memtest one all night and briefly run cpu test. Maybe I should work on those tests.

Traditionally, I've been able to figure out the problem component by eliminating everything that works. The things that don't work would manifest themselves easily after running the standard set of tests.

That sounds like my last i7 build...rock solid. I think I will try the 1 stick of memory test this weekend and see if it is more stable.

I posted that because I can't get gigabyte to respond to my problems. There is no phone number and it takes weeks to respond over their "web forms". I saw that they were pretty active with responding to customer reviews so that is why I did it.

I've also called Denon and Intel...multiple times. Everyone points the finger at everyone else. I've spent countless hours already troubleshooting this machine. If you read ANY of my other posts listed here, MY EFFORT has helped a number of other people with some of the EXACT same problems. So yea, I think it's plenty fair that I light a fire under someone. Thanks for the lecture though on doing my due diligence.

I choose the 661 because I wanted a bit more horsepower than the other CPU/GPUs. I planned on doing my rips and conversions on this machine.

As far as the 600 series, I loved the thermals of the design. Very low power and would be put into a small case without the problems created by installing a full sized riser board. Most small cases have smaller PSUs so I didn't want the extra power draw with a separate video card.

My last i7 build was rock solid, handled bitstreaming no problem, full audio but ran really hot and the case was the size of a large AVR. I didn't want that this time.

RMAing anything from this machine is really problematic because it is about a 3 week process to get an RMA, send it, receive it, resend new parts, install new parts. In the meantime, I have a wife and 2 four year olds without TV/movies/dvr. That doesn't make for a happy wife which makes daddy VERY unhappy. A week without American Idol for my wife is like a week without air...so when I RMA something, I need to be absolute sure it IS the problem. If not, I have just inflicted weeks worth of pain and aggrevation from my wife only to repeat it by RMAing something else.

I have been building machines for over 15 years and can tell you I have identified problems FOR manufacturers well before they publicly acknowledge the issue. I've worked directly with Microsoft .NET creators a year before they even released the first version to the public. I've identified problems with a batch of resistors Compaq used on a revision of their boards that caused "excessive" noise along the bus. I spent time on the phone with OS product managers at Microsoft...even had correspondence with Balmer. I exhaust all my resources and I'm really good at my job. I'm not sure if you are calling me a noob or not but I am about as far away from noob as it gets when it comes to computer hardware. It's hard to read the "tone" of your email so I appologize in advance if I read into this.