You're correct TheDoctorG. I am now able to offer yet another confirmation that baking does resolve the issue. Thanks to Richlove and all the others for taking the time to post their experiences and results.
For those of your who think that being insistent, polite or whatever to get your cards replaced are just spinning your wheels unfortunately. As others have repeatedly pointed out, those replacement cards have the same issue and will ultimately show up again with the "new" cards which in reality have been sitting in a warehouse somewhere for 3, 4 or 5 years.
I am a Mac guy now, and have been since 2003. Prior to that, I built my own PC's and I am an IT Network administrator by trade. I don't work on Mac's in a business environment, so I didn't have the suction cups and to be completely honest, I had never even seen the inside of my own 2010 27" iMac until yesterday. Not sure why, but I was actually nervous to do this, and I put it off and stayed on Mavericks as I too had horrible results trying to upgrade to Yosemite. My iMac works great in every other respect, and I felt I was forced in to going ahead with the bake simply because I wasn't going to waste money on a repair that I knew wouldn't ultimately fix it, I couldn't sell it in good conscience, and I couldn't throw it away and buy a new one knowing that the problem was actually so minor.
I ordered the cups from iFixIt, and went ahead and grabbed a new set of the tools while I was there. I very cautiously took my iMac apart following the instructions posted in this thread previously. Baked at 400 for just over 6 and a half minutes (oven was preheated). Once the card had fully cooled, I applied fresh heat sink compound and put it back together. It struck me on the re-assembly that it really isn't all that different from taking apart any computer, but for some reason, the Mac's just had this mysticism in my mind which made me nervous. I cannot explain why that was the case, it just was. Booted up, no issues! Upgraded to Yosemite, no issues. Ran for 24 hours, still no issues, with power saving back on and using it as I normally would for both low stress and high stress activities (like games).
I cannot recommend this for anyone who is not VERY comfortable with working inside a computer. For those folks, I know you're frustrated, but rather than going to Apple, who unless they install ovens at the Genius Bar is actually unable to permanently resolve the problem. Find a local computer store who will work on Macs. Show them this thread and ask if they are willing to do the work. A lot of those folks have probably heard of the baking method as it's not a new procedure for fixing this kind of issue with circuit boards. Even if they won't do the bake at the local store, they may be willing to remove your card and reinstall after you do the bake yourself.