Terrific Tom ... As you know, I too am running my hive foundationless. My biggest concern was (initially) that commercial foundation potentially contained contaminants - and there were even reports that some foundation contained paraffin wax, I had no desire to see such things presented to my bees.
I started my beekeeping journey with a swarm and just one (borrowed) frame of drawn comb and four foundationless frames - the hive was dummied down to this size and I used the triangular strip of wood with a layer of (Th*rnes best organic) beeswax painted on to them. I'm running 14x12 frames, wired with three horizontal stainless steel wires - I made my own simple frames this year but I bought some Th*rnes seconds in the sale for next season. For the cost it was barely worth making my own.
It was only a moderate sized swarm but they drew out the first four frames in less than a week - I then just kept adding a couple of frames, usually at the ends, but keeping the hive dummied down. It was a bit of a faff as it meant I was constantly making or modifying crown boards to fit the brood nest size but a small price to pay for seeing the comb (and the quality of the wax) develop. I fed them with about 5 litres of 1:1 syrup when they were building the first four combs but after that let them find their own building materials.
I haven't found any problems with them building anything other than straight comb and my bees have, mostly, filled out the frames right to the edge (and because I made a mistake when I built the hive) sometimes 2" on the bottom of the frames as well.
Other than this, my experience, has been very close to everything you have so well described. My bees are gentle and well mannered, they have been disease free and as of the end of the season devoid of varroa. I put all of this down to luck but having read your account I am more inclined to think that bees allowed to behave as they see fit may be less stressed and able to counter the various adversities they face more effectively.
My hive expanded to 13 frames of drawn comb and was very full of bees by the end of August - they stopped drawing comb around the middle of August (well - they added a half frame after that inspection but it remained empty until they really started to build up the honey stocks for winter).
The drone situation was very similar to yours but around the end of August the drone population reduced dramatically and I noticed that the bees had converted a lot of the previous drone comb to worker size - and then filled the cells with honey. I used drone cell uncapping regularly to check the varroa situation (although I never found any !).
I didn't have any supers on the hive this year and I've left them all the honey that they have stored ... the hive was quite full by September although stores dipped a little at the end of August and I fed them some 2:1 to keep the stores levels up. I understand that the 'August Gap' is not unusual. If there is honey left in Spring then I will take some frames out then, for extracting, and put them back empty. Perhaps keeping one for my bait hive.
I have no experience of using foundation - except in my studies and visits to other apiaries and the association apiary but I'm not on a crusade. Foundationless has been a very positive experience for me and I would encourage anyone thinking about it to give it a try. If your comments about bee behaviour are anything to go by (and reflected in my bees) then for this alone it is worth considering.
Thanks for spending the time to relate your experience - it's valuable coming from the perspective of someone who has more years of beekeeping than I and having used foundation as well - so you are able to draw a comparison.
I will certainly be continuing foundationless in the coming season - whilst there may be some loss of honey production I am, like you, not that concerned. In my case, having nothing to measure honey production against, I won't miss what I have never had.
I'm happy - the bees appear happy - what more could a beekeeper wish for ?
My foundationless frames from the arrival of my swarm to the last inspection of the season can be viewed here:
http://www.flickr.com/photos/99514363@N06/sets/
Tin hat on ....