-high, it shouldn't unless you have other processes actively using your CPU but it would be better to just have those other processes off.

snd_mixahead 0.05, didn't notice any real FPS change and I'm not even 100% what this command does so I'd rather leave it default.

-edit- was informed what snd_mixahead is, I'll put it at .05 even if their's no FPS benefit

ai_expression_optimization 1       // Disables NPC expressions when you can't see them, not sure if it works on regular players in TF2, but that's why it's experimental.
//r_pixelfog 1                     // Supposedly increases FPS via fog, but it doesn't seem like it. Feel free to play with it to test. I'll run benchmarks later.
fast_fogvolume 1                   // Undocumented but I didn't experience any FPS loss with it enabled, will run benchmarks later.
filesystem_native 0                // I think there's an FPS gain with this, anyway.
host_thread_mode 1                 // runs host in threaded mode if multicore

Just tested the rest of these none of them seem to provide any boost.

http://teamfortress.tv/thread/20172/my-fps-config

The thread isn't that old, but I'd venture to guess the majority of the people who hit other are using my CFG, m0re's, or Stabby's.

I hit other cause I use my CFG.

1 of 2 things probably happened
1. Your PC took to long to load and it counted frames while it was still loading the demo,
2. 1 of your experimental commands effects rendering in very odd ways

Did you run 2 different demos cause the number of frames should be the exact same. Specifically the 2639 Frames is the one that was provided in the benchmark thread.

Out of combat idle their's a lot of people who get 500+, in combat like a mid-fight for 6s majority of people with even really good pcs are around 230-280 for most of it. HL and pub fights I highly doubt anyone gets over 300fps.

I've had this issue very briefly too, remember changing a few mouse settings and haven't had it again...

I think I remember now exactly what was happening for me.

The Mumble overlay had glitched out for me and my mouse would lag by like 3-5seconds. I could stop moving my mouse wait for my cursor to go unresponsive and then shake my mouse and stop, and I could then watch that movement happen. I fixed this by disabling the mumber overlay...

Their's also Flash, Tape, CD, Floppy, Blu-Ray, DVD, Liquid (experimental), plus A LOT more.

Also try squeezing in a 32 or 64GB SSD it's Well worth it.

ai_expression_optimization 1       // Disables NPC expressions when you can't see them, not sure if it works on regular players in TF2, but that's why it's experimental.
//r_pixelfog 1                     // Supposedly increases FPS via fog, but it doesn't seem like it. Feel free to play with it to test. I'll run benchmarks later.
fast_fogvolume 1                   // Undocumented but I didn't experience any FPS loss with it enabled, will run benchmarks later.
filesystem_native 0                // I think there's an FPS gain with this, anyway.
host_thread_mode 1                 // runs host in threaded mode if multicore

ai_expression is definitely just for the AI and alot of other commands disable expressions
r_pixelfog I tested it's definitely not helpful turned off in Dx9 at least with a FPS cfg might be helpful in a High Quality CFG, and does nothing in Dx8

filesystem_native 0
host_thread_mode 1

These seem promising, but I have a feeling host_thread_mode is going to only affect local listen servers but I could be wrong.

Forgot to mention I also added

net_queue_trace 1
pretty sure this will help with optimizing the net code for TF2 but I could be wrong.

I've had this issue on Windows 7, and Windows 8.1 on 2 different systems (I used the installer both times and setup the Aspect Ratios for what I was using)

Win 7 PC is at 1920 x 1080 16:9

Win 8.1 PC is 1680 x 1050 16:10

I'll get pictures after work today.

I've tested basically every allowed command from here
https://developer.valvesoftware.com/wiki/List_of_TF2_console_commands_and_variables

btw their's A LOT of really unstable commands to either enable or disable.

Updated the CFG

r_occlusion 0 // disables ambient occlusion. 2% FPS boost

// ----------------------------------------------------------------------------
// Test Shit
// ----------------------------------------------------------------------------
cl_localnetworkbackdoor 0 //Network optimizations for Singleplayer, disabling has about a 1-2% fps boost
cl_cloud_settings 0 // I believe this disables cloud syncing of CFGs but not 100% sure
//cl_notifications_show_ingame 0 // Pretty sure this disables Trade/Duel Notifications
sys_minidumpspewlines 1 // Basically the number of lines saved to a log file from console. No FPS boost but 15% lower FPS variance
cl_loadondemand_default 0

I can't believe I missed r_occlusion in the past, was literally a no brainer.

Before (framerates are overall lower do to the last update with full moon mode on)

2639 frames 12.561 seconds 210.10 fps ( 4.76 ms/f) 9.532 fps variability

After

2639 frames 12.243 seconds 215.55 fps ( 4.64 ms/f) 9.587 fps variability

https://dl.dropboxusercontent.com/u/92187841/gfx.cfg

-edit-
Until the TF team releases new commands or makes some noncheat required it's going to be extremely difficult to find new settings spent roughly 14hrs this past week testing nearly every allowed setting in the game...

If you don't need the other monitor while playing you can open up your active displays and disable the other 1.

Right click desktop > screen resolution > click on the display you want to disable > next to the field that says "Multiple Displays" click the dropdown menu and hit "disconnect display"

and when you're done playing you can reopen that display by going through the same menu.

Sorry if this really isn't an option for you.