At the risk of shameless self promotion, you might want to try the Santa Fe Linux Live CD
to see what it does. It autodetects and configures the nVidia binary driver at boot. Then
you can use the different CD boot options to figure out exactly what hardware is giving
you trouble. In particular, the oddly named SantaFeAMD boot options will disable apic,
acpi, and will force the use of the bios irq table. If it does work, then its not a hardware
issue.
The next culprit I saw building Santa Fe was the use of thread safe libraries. I had to
manually remove the libtls libraries, rebuild the driver, remove them again, then ldconfig
the system before I built the iso. Otherwise, the kernel module that worked on the
last boot wouldn't load on the next boot. Of course this was under a 2.4. kernel so I'm
not sure exactly whats changed for 2.6 but its an idea.
The iso is at
http://www.santafelinux.com
Rafael
Author, Santa Fe Linux