Hello,
Overlap section is a brighter then the rest of the image. All projectors are new and set to the same settings, I have tried all the different profiles. PLease see the following pictures which includes my image setup.



It sounds like something strange is happening with NTHUSIM. Can you do us a favor and export your configuration file for us to have a look at? I just want to make sure there isn't something in there that is confusing the software somehow.
To export the configuration file, go to the Tools page and hit the Backup button.
Definitely very strange!
Definitely something not normal occuring. When you are in-game the blends should be seamless. Something is no rendering correctly in your pics. I use those same games on my Tri-SLI GTX470 setup and the blends are correct. Might be a quirk in that version of NVIDIA drivers? Which NVIDIA driver version do you have installed?


When you toggle the spacebar in configuration how does the blend look then? It looks to me that you picked the wrong profile setting with the center mouse scroller. Pick something around Blend Profile 8-12. Your blend alignment overlap looks good, it's just the blend profile looks wrong. Looks like it's set at blend profile 0.
Which Windows version are you running? Do you have the current DirectX runtime installed?
http://www.microsoft.com/download/en/details.aspx?id=8109
Overall the setup looks good. If possible please do a setups page. I like for there to be as many examples as possible in the setups so others can better understand different ways to setup their hardware. Keep us updated on the progress of the build.