I agree, don't see a significantly better version till they move to 28nm. That said I expect it to get faster - the 58xx series is now 6 months old and very closely based on the 48xx anyway so drivers are gonna be close to optimal. You've got to expect pretty big improvements for the GTX 4xx cards as they are brand new with a brand new architecture. That's probably significantly more important then unlocking another 6.7% cores.
Do they have 40nm? No, with them you get 45nm and future promises, with TSMC you get 40nm and future promises. Global foundries is a good option, but it's not in front of TSMC when it come to manufacturing. Equally if you think you have better hardware almost better to cover your competitor by using same manufacturing, then risk going somewhere else.