Don't know why the flats would clip the stars Paul? looks to me like they haven't been protected enough while sharpening or,the sub exposures were slightly too long for the luminance....did you have a reducer on the ED80? at the native f/7.5 I would think you could go to 10 minute subs with the dynamic range of the Kodak 04020 chip.
The water cooling will be worth looking into for those worm summer nights when you need the cooling the most.
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