You might try installing your old GPU and underpower it to see if you see similar behavior during startup - i.e. leave a 6-pin unplugged and see if you get the same freezing halfway through booting. Maybe someone who knows more about this could comment if that test is safe and wouldn't do any lasting damage?
Also, hindsight being 20/20 of course, if you had used the card unflashed before sending it off you might have been able to rule out another variable.
Also: was your old card a 2 x 6-pin? If it was a 1 x 6-pin it is also possible that one of the power ports on the logic board is bad and you would not have known it with a 1 x 6-pin card.