Kristian,
While not the 40d, I made the switch from a 10d to a 1dm2n - and have not looked back. Two primary (can you have two primary?) reasons were the 45 point AF and the larger sensor. With the 1.3 sensor, the 17 is almost wide now - something I was sorely disappointed with with the 1.6 sensor. I figure I also am not yet using the weakest portion of the lens - the extreme corners.
I was doing BIF, and the 10d with the 7 point AF was - well let's say I can function better with the one series 45 pt system.
I've learned to absolutely love the feel - the heft is not a big issue - in fact it may help control the mirror slap at slow speeds - that is just conjecture. Though you will not notice moving from the 40d, the startup speed, and the read-write speed to the cards is light years ahead of the 10d. The 2.5" finder was a welcome change from the 1.8" on the 10d.
The adjustability of the camera is beyond amazing - I still have work to do on that front.
If you're going to a 1d3, then menuing will be much more in line with the 40d - earlier models, like mine, are different, night and day, with most everything being 2-button + dial or wheel. As long as you are not going back and forth on the same job, there will be no problem.
I'm at the point where I do not think I want to shoot anything but a one...