Thanks Paul, for letting us know!
I never did work out exactly how many keys were needed to find the bug, it was possibly only 8 or 9 with the standard 6 key + modifier style report. But it was definately related to reports where some keys were reported as bits (e.g. modifiers) AND some keys reported as bytes (e.g. other keys). My firmware, which reports all keys as bits, didn't find the bug, but it's still nice to have it fixed :-)
Any chance of a patch for XP? :-p