OnBoard: Thanks for the info. I opened my eyes and wolf2009's CPU load is right where it should be when testing so it's not that. I was helping one user who had CPU Usage at around 25% because one core was at 100% when he thought he was idle. Hard to calibrate under those conditions.
The reason I originally chose TjMax=95C is because using TjMax=100C implies that there is a huge, sh*t load of "slope error" in some of these 45nm sensors. I was being too kind to Intel.
I re-tested a 45nm E8400 - C0 and a 65nm Q6600 - G0 and I set both of them to TjMax=100C. I took both of them up to about 80C and a little beyond at times

where sensor error is minimal and measured the IHS with the IR thermometer again. When using TjMax=100C, the hottest measured spot on the IHS is always 5C less than the RealTemp reported temperature. I spent half an hour and moved the IR thermometer around and around at various temperatures and that was as close as I could ever get. The CPU covers a very small area of the IHS and heat dissipates very rapidly at these temperatures that a 5C gradient between IHS temperature and core temperature is not impossible to believe.
These pictures were taken about 2 seconds apart:
Intel showed that TjMax is not a fixed number and does vary by a few degrees but they didn't release how much it can vary by. It might be plus or minus 2 or 3 degrees or more. There's no way I can buy a large enough sample of processors and test them all to come up with an average range of error. Intel knows these details but they have decided not to release any additional information that is necessary to write an accurate core temperature monitoring program.
TjMax=100C might be an absolute maximum and the average processor might be a few degrees less than that. As I said on XS, releasing TjMax for 45nm processors was nice of them but so much additional information was left out that enthusiasts are no further ahead. They mentioned slope error but didn't show how large this amount can grow to. With the two Quads on this page, it can obviously grow to be quite large.
The 65nm Q6600 and other 65nm Dual Core CPUs I tested do not have the slope error that my E8400 has. Core0 and core1 on my Q6600 are very consistent and track each other closely from idle to TjMax. At low volts and low MHz and with no correction, they report a core temperature of about 6C over room temperature at idle. Considering how little heat they are putting out at this setting and how much heat a large air cooler can dissipate with the fan on max, this seems reasonable. 45nm CPUs put out less heat at the same settings compared to a 65nm CPU so there is no way that they should be idling at a temperature way higher than a 65nm processor.
All I can do is increase the amount of slope correction that RealTemp allows you to do maybe from a maximum of -9.9 to a max of -19.9. This will give you some more flexibility and should let you guys get your 45nm Quad temps down to a much more believable range. I wish Intel gave me more info to work with but they haven't. I'll post a link here when the next beta is ready.
It will be interesting to see how RealTemp tracks your CPU reported temperature.