CHEs are actually MUCH better for the humidity than infrared bulbs.
EDIT: i completely skipped over the part where you explained that the CHE wasn't working for you. my bad! but IMO i find CHEs to be better for humidity than IR bulbs. is heating the room an option? other than that, you're only other option is bulbs, or a PVC enclosure + RHP.
i used a 100 W CHE on my 20gal with its rheostat turned up only a little. i'd say you could use a 150 W with a 40gal with plenty of power to spare.
what are you using to measure the humidity with?
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