First of all:
Sorry to hear about your misfortunes but glad to see that we were able to clean things up.
From what I can tell on my GPU, it give out a moderate amount of heat during startup. Its only durring 3d apps. does it really start giving off a lot of heat. I was planing on powering on the pelt and the GPU at the same time. So from what you are explaining, this is where my condensation problem will come from; freezing the chip during startup then running a 3D app. and risk melting the ice.
Another consideration is that I can only crank up the core clock after I get into Windows so there is a time where the card will be puting off even less heat. Sounds like a three stage issue; standard clock (during powerup), OverClock (in Windows and 2D apps.) and Full Bore (3D intensive apps).
I suspect that the GPU will give off about 20W of heat during the first two stages and then about 45W during the last one. With those assumptions the 85W in theory should keep the card well frozen during all those times.
I also plan on doing a voltage mod to the core so that will increase the heat load as well but that should be across the board.
Bummer, with this new information, it sounds like I have no choice but to find some neopreen to avoid another dead board.
Hmmmmmmm
BTW the humidity where I am is not too high, say 60% on an average day.