Thought it's about time I posted an update after months of debating, reviewing, wrangling and spending...
The workflow so far now consists of:
Nikon FM3 >> Rollei IR400 film >> Minolta Dual Scan IV >> Apple Aperture v2 >> HP9180 >> Sihl Paper.
...the new changes being the film, use of Aperture and the new printer.
The Rollei IR400 film scans beautifully, without exagerated grain. I've pretty much given up on it's IR capabilities, but instead use it as a normal 400iso B&W film.
Apples new Aperture software is more than proving it's worth for b&w work. To be honest, photoshop is overkill for what I'm doing and aperture gives just enough - similar to lightzone, but a more pleasant experience to work with.
Finally, the HP9180 printer is the star of the show. Both b&w and colour rendition is fantastic right-out-the-box. I have suffered from pizza-wheel marks, but only when I use HP Advanced paper, which is a bitch to use at the best of times and (imo) doesn't produce good results.
I've been using printer paper from a company called Sihl. They're eastern european, very cheap and, so far, produce really excellent results for normal 'regular use' printing - far better than the off-the-shelf paper offerings from HP or Epson. I'd say for showcase work, I'll need to invest in some Hahnmule paper, but I'm still plucking the courage up - it ain't cheap.
One thing to fix and one thing left to change...
I'm chasing a problem at the moment with the Aperture/HP9180 combination. The prints are coming out incredibly dark (at least 2 stops) compared to the screen. This will probably be the subject of another posting shortly.
The final thing I need to change is the scanner. I've done an incredible amount of research on the available scanners, the theory, etc, etc. The end result will probably be the purchase of a 'Reflecta' scanner. This is a german brand who don't seem to be around much in the UK or rest of world. The output of these is very comparible to the baby Nikon, but without the expense or snobbery associated with the Nikon brand!
Thats all for the moment - hope the comments help!
Mat