Ok experimented with affinity.  Oddly enough it does not change the hashrate of AMD cards.  It did however, drop my Nvidia's from 130MH or so to 6MH when I set affinity to one core.  No idea why.

Not skimping on the PSU for sure as you said.  No you're right that cheapest is not the best.  I feel I've just been as efficient for MH/$ that I could be.  Of course I could be more efficient as well.  Thanks.