Good thing you don't live on the Panhandle. I do recall driving through there (on the way to Orlando) and there was enough snow/ice on the road for a trucker to lie down his rig on the side, blocking everything - 25mile traffic....good thing I was going in the opposite direction. So, yes cold can happen in Texas :>).
Can't say anything about foam insulation. But, if you do exterior diligently any conventional (fiberglass) insulation will cover any light that may try to squeeze through. Also, what sorts of walls are you intending to install on the interior, OSB ? I can smell the formaldehyde all the way here :>).
Any water coming directly from the hose will likely be too warm to use in the darkroom, no ? Urrr, unless it's 2AM.
Yes, the Panasonic "whisper" type are really good. I have one in the bathroom (less than 3' from my ear) and v. often I forget it's there at all. I also used Ultra Silent Broan throughout the house, and they are v. quiet as well - not sure of the availability of this.
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