I'd try measuring some voltages with the system running (under a heavy load would be best). Easiest would be the 5V and 12V pins on a loose molex connector. Don't trust the voltage readings in the BIOS, sometimes they're way off.
It would be very informative to measure the onboard 3.3v rail, but doing that is more tricky. You'd need to find a safe point to measure it from.
If I understand correctly, the original PSU is ATX, and not just the modern one that you temporarily swapped. So nothing you've been doing ever involved the AT connector?
As others mentioned, these type of boards will have an onboard 3.3v regulator which might be inadequate or possibly damaged if it was overstressed. However, when it's running with ATX, I think that onboard regulator would most likely be bypassed. Actually, on a Tyan board that I looked at, the onboard regulator was in parallel with ATX 3.3v. Seemed kind of odd to bridge them like that, but that's how it was.
PCBONEZ wrote:Max amps for 3.3v on a 1x/2x AGP slot is 6 amps.
It's just under 5 watts for two sticks of SDRAM (I don't have data for modules smaller than 256Mb though), so ~1.5 amps or less.
Unless there are other 3.3v loads the regulator would only have to handle 7.5 amps.
Part of the CPU power also comes from 3.3v. According to my old notes, for the K6-3 450Mhz, max Icc3 is 0.66A.
Single voltage 3.3v CPUs are much worse - some are in the 4-7A range. However, depending on design (and jumper configuration) they might get helped out by the Vcore regulator. Anyway, he's not using one of those.
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@AaronAsh
Although it might not solve the immediate problem, I suggest trying to get hold of a quality ATX PSU to replace the generic one. Cheap power supplies can be problematic in general, and can have noisy output voltages that can be stressful/damaging to components that are exposed to them. That said, choosing a quality PSU for that era of machine is a bit of a controversy in itself. Modern PSUs aren't optimized for the kind of loads that appear on old systems (mostly 5V / 3.3v with little 12V), and old PSUs (even the good ones) often need to be recapped.
The Windows startup to a black screen sounds like an AGP problem I had on a Tyan VIA MVP3 board. In my case, I think the black screen portion of the problem was solved by enabling onboard USB in the BIOS (seriously). However, your chipset is an ALI which I have no experience with. The non-Intel AGP chipsets from back then are quirky.
It's interesting that you once had it boot to the GUI and show a corrupted desktop. I don't know if that represents something more serious.
As far as alternate motherboard suggestions:
AGP with super socket 7 is inherently frustrating territory. At that time, the only solid implementation of AGP was on Intel chipsets, which of course don't appear on Super 7 boards. PCI cards can avoid frustration, otherwise you may have to fight with settings and drivers to get AGP working on these boards. I'd definitely leave AGP set to 1X. 2X accomplishes nothing in this speed range and just reduces the chances of success.
If you want AGP to just work, a slot-1 440BX board is a great way to go. They don't have the same underclocking potential as super 7 though.
Intel slot-1 boards are great quality and common (a fair number are even out there as NOS), but you have to be careful that the board is truly ATX. A lot of them are Dell versions which at the time had their own PSU pinout. Intel boards also won't let you underclock.
Asus slot-1 BX boards had good caps and will allow tweaking, but they tend to be expensive. Every other brand I can think of usually have bad caps so expect to need to replace them.