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Nice one Simmo! The repro looks really great compared to the original ones, you've done a great job with that.
Looks like you're really pushing the boundaries of what you can get out of an uncooled dSLR now, in our temps. Not sure how the 40d goes noise wise either; there's likely to be newer models with better noise performance which could be picked up at relatively little cost (e.g. the Nikon D5100, although that comes with its own set of problems with software support). But then you've got it Ha modded so that's another additional cost.
A home made cooler box does sound like a good investment as you might be able to significantly improve your results with little outlay. I believe Orion also make some cooler boxes for Canon dSLR for a few hundred $ that don't require any ice (peltier driven I think) so they reduce the risk there.
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