A couple of thoughts. You don't have to evaluate the DOS at the same k-point sampling as used in the calculation. If you calculate the 30-kpoint case with 40 DOS k-points, do you see a difference? That is, it might not be a matter of k-point sampling for the calculation (30 or 40 should both be plenty enough), but that of the DOS evaluation.
For a spin-polarized calculation (and it really looks like there is a strong polarization) you also should take care that both calculations converge to the same spin state. You don't control the initial spin, so maybe they converge to very different states?
Finally, just to be safe, I would also make the unit cell a bit larger in X and Y to avoid interactions with the periodic images.
Not saying that any of this will magically solve the puzzle, but it's some points you can investigate.