Is there a non dangerous way to test if a pad is needed or not? Don't want to blow up a chip because it needed a pad and I only used grease.
Honest answer: I use pads on my jallies that have the old and new style chips (the newer ones are lower profile) on the new chips only. On the old ones I use a dab of Radio Shack $2.00 thermal grease.
Where I win is putting thermal grease on the bottom of the jally, then either putting the bottom plate on or another heat sink. Do not underestimate how much heat you can draw off the bottom of these things.
C