I would definitely take Thurston up on the sizing offer. I ordered my Dustbowl through them and we seem to be fairly similar in size (I'm 6'2" versus your 5'10"). I'd be careful about sizing the Dustbowl down too much. I think that the pictures (particularly the back) can make it seem boxier than it really is. My initial pictures of my 42" Dustbowl:
http://s867.photobucket.com/user/nwanzenr/slideshow/Aero%20Dustbowl
I've since adjusted the straps to give is a more fitted look. For me, a size 40 would be too small (let alone a 38). As a point of reference, here are some shots of the D-pocket Norshore that I just received (also size 42):
http://s867.photobucket.com/user/nwanzenr/slideshow/Norshore
http://s867.photobucket.com/user/nwanzenr/slideshow/Aero%20Dustbowl
I've since adjusted the straps to give is a more fitted look. For me, a size 40 would be too small (let alone a 38). As a point of reference, here are some shots of the D-pocket Norshore that I just received (also size 42):
http://s867.photobucket.com/user/nwanzenr/slideshow/Norshore
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