Resolution!!!
Thank you for the suggestions which led me down the path to discovery. Turns out the guides are incomplete (imagine that!) Here are some findings:
1. Just because a rig will run and cgminer shows both cards as being used, it may be a lie (like cake).
2. If you have two cards (possibly more, someone else will have to verify this) which seem to balance the expected max hashrate for one, and their hash rates flip flop when Intensity is adjusted, it probably means only one card is being used, but the stats are for both. This is a tip-off that something is astray.
3. If one card has high temp like 70C while the other is low like 38C, that's another tip-off that one card is not being used.
4. If you plug a monitor into both cards and then fire up cgminer, both cards get recognized and used, my current numbers with the settings as above without any tweaking are now 544 kh/s for GP0 and 570 kh/s for GPU1. Point here though, is once cgminer is cranking along, you can remove the monitor cables from the rig and both cards still get used as they should. I will get dummy plugs, but for now the cards only need to be plugged in to start cgminer, so it's not really a big deal.
I hope this helps someone else down the road and thanks again for the help from the GoldCoin community!
3lw33xi / gaz