The Final Verdict:
Got off work today and back to trying to track down the problem. The first thing I did was unplug monitor #2 from card number #2 and plug it into card #1 (effectivley giving me the same setup i use to have just with a new video card). I booted into my old XP Pro drive and set the dual monitors back to a spanned desktop so i could get a baseline of performance of the 9800GTX 512 vs the 8800 Ultra OC 768.
No fuckin joke, the 9800GTX smoked it hands down and I can now run through shat or ogr or sunwell with all 5 toons on one box at a whopping 40-50 fps. I couldnt be happier except if i woulda saved alot of money and just purchased one video card :p
Vista64 - dont bother, for 5 boxing on one machine vista is a waste of time, Xp Span mode is where its at.
Memory - Anything more than 4Gb is just not needed as has been mentioned by a few members of this forum before.
Dual Video Cards - I dont know why but this just seems to do nothing for us trash except trash our fps.
After reading all the reviews about the 9800gtx and most of them reflecting that its a trade off back on forth against the 8800 ultra i was very surprised, to be honest it did perform better in thier tests without AA running at some silly number so for 5 boxing wow this is one sweet card. Should be interesting to see how it holds up on an 8 hour run of high pop areas, ill report back on this later and let you all know.
I'm so happy to be running through cities 5 toons on 1 box at 40+ FPS - Goal Achieved and thanks for all your comments guys! :thumbsup: