I wonder if they redeisnged the mirror and whatever mounts the
mirror. I think the mirror placement would require very tight
tolarances. I don't see how that can be done w/o using metal mounts.
if you take a look on nikon's d40/d60, they also made of plastic, but
they have much better AF then canon, so I think the problem was not
caused by the plastic, I think the real reason that caused Canon's AF
is that the AF sensor (not the image capture sensor) if you flip up
the mirror you will see there is another croup of sensor that only do
AF focusing just below the mirror, what I believe is that Canon has
been using cmos type AF system in most of their camera, and this is
what I believe the main problem, you know cmos has a nature of
sensitive to weather and cmos will produce more noise than ccd under
dim light, so no matter how to send the camera to canon to fine tune
the AF, the focus is still very up and down.
and I believe this is what cause the 1d/1dsm3 AF take 3 years to fix,
canon have been using ccd AF sensor(not the image cature sensor)
since eos 1 film camera and have been great AF, maybe they decided to
cut down the cost, so they decided to cmos as their AF sensor
starting from 1dm3, and this is why some people believe 1dm2 is
better than mark 3