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No further progress here although I'm planning to use the ASI 120 in cooled mode once I complete my Canon exposure experiments. If I can acquire another 450D or even an 1100D I'll take the plunge and do the IR mod on one and investigate a cold finger mod.
The dew problem seems to be the big bugbear. I have it resolved on the ZWO 120 with it's sealed front cavity and desiccant system so for now I'll experiment with that.
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