Maybe I miss something in the process (sorry if it's the case).
Here is what I did :
I check the version of my SX40 with both ver.req and vers.req uploaded on a 4Go SD via a card reader.
Fine, it's a GM1.00f like you.
I Upload your fresh DISKBOOT.BIN and PS.FI2.
I grab an CHDK folder (the wrong part?) of a SX30 1.00E here :
http://mighty-hoernsche.de/Upload CHDK folder + your DISKBOOT.BIN + your PS.FI2 on the root of the 4Go SD via a card reader.
I don't lock the card, insert it in the SX40, switch it on, turn the playback mode, go to the bottom of the menu.
I don't see "upgrade firmware".
Then, I try with an "f" version of the CHDK folder (exactly the SX130IS 1.01F) and restart the thing.
But the same, nothing.
So, what CHDK folder do you use ? any importance about the "letter" version?
May I boot with CardTricks (I a PC user).
Anyway, I'll try again now.
I'll be pleased to use the RAW.