This whole testing fiasco is really a wonderment. To lose that many precious (and expensive) chips to only gain a marginal amount of useful information is insane. At any company I have worked for that kind of decision would have landed someone a pink slip.
To be fair, the cost of a processed 65nm wafer is likely somewhere between $1500-$2000. Not exactly a fortune.
Avalon pays (it is estimated) about 4k per wafer at 110nm.
How is BFL paying half that at 65nm? Somehow your estimates sounds kinda off.
110nm is an old technology. You cant expect GH from that. If it was possible the miners with Cyclone and Spartan FPGA already can be made. They aren't so dont be fool to be involved in this ASIC hoax. Also 67117 in btcguild is proxy pool.
regards.