TLDR at the bottom.
I’ve done some additional testing and further narrowed down the overheating issue I encounter. The failure mode I see is that when playing Battlefield 6 for >15 minutes the GPU’s power usage will alternate between very low and very high values, this results in an a consistent microstutter about once a second that’s very noticable, and validated with the in-game report graphs. Over the weekend, I tested the following configurations:
dGPU not installed (using fan shell): CPU temp ~75c (no microstutters observed)
dGPU installed, game running on iGPU: CPU temp ~85c (no microstutters observed)
dGPU installed, game running on dGPU: CPU temp 92-100c (microstutters observed)
It would take almost exactly 15 minutes for my system to encounter the microstutter issue from a cold-start. This was very reproducible, I probably recreated it this way ~10 times. Noticing that CPU temp’s increase with increasing interaction of the dGPU, I decided to try some simple modifications to restrict hot air flow from dGPU to CPU. I did this by adding foam seals around safe points on the expansion bay that didn’t interact with anything it shouldn’t IMO.
Restricting the airflow from dGPU to CPU side increased the time it takes to encounter microstutters by ~5 minutes (33%), but did not stop it all together.
Interestingly, I do not see a performance difference between dGPU and no dGPU as when I ran cinebench without the dGPU I got the same score.
If I strip the top of the laptop down such that there is no midplate and the motherboard is exposed while I am experiencing the overheating-microstutter, the microstutter will go away a couple moments after the airflow has increased.
My replacement heat sink arrived yesterday, and I installed it unmodified. I had a theory that when I removed and reinstalled the heatsink last time to do my LM → PTM swap, the pink thermal pads (under the metal plates I highlighted above in my previous post) were not created as good of a thermal connection to what I assume are some power regulation component. The thermal pads stayed deformed in the shape of those components, and the basis of my theory was that unless I mounted it back exactly how it was mounted before, there would be tiny air gaps, which could explain that being a hot spot in the thermal imaging. This however, did not resolve my microstutter issue, and I’m well aware that the hot-spot on the thermal image could also be explained by the fact that the heatsink at that location is just a copper plate and not an actual heat pipe, which is less effective at transferring energy.
Side note: I also noticed that my dGPU screws were very loose. One of them was so loose, that I’m not sure it was even doing anything. I tightened them down to finger tight, but it didn’t seem to affect performance in any way.
Second side note: replacement heatsinks do not ship with a PTM pad. I had ordered 3x extras so I could do multiple experiments, but after finding out that the heat sink doesn’t include one and accidentally destroying the first one I used, I now only have 1 left.
Third side note: My microstutters does not appear to coincide with any temperature sensor I’ve been able to monitor on HWInfo 64, assuming that 100c is the threshold to be looking for. If there are other arbitrary thresholds, I’m liking missing it.
TL;DR;
Installing a dGPU increases the CPU temperature, and using said dGPU further increases CPU temperature. Replacing my heatsink did not resolve my heat-soaked microstutters, but restricting dGPU side ↔ CPU side airflow does seem to help avoid the stutter for longer.
Given that my CPU was running at 75c with the dGPU uninstalled, I’ve become less confident that doing the copper shim mod will result in temperature drops, and it seems to likely be more air-flow bottlenecked as the cpu heatsink gets less airflow when the dGPU is taking most of it.