Hi,
I would say you really need your son's consultant's input as far as adjusting his carb/insulin ratios whilst playing intensive sport. In fact, the team should set up ALL his doses for you, his basal, bolus ratios and insulin sensitivity ratios. They have formulas for working these things out, based on his data before going on the pump, and then doing lots of testing and record keeping for some time after. In some ways it's a bit of trial and error, but it should not be left up to you to try and work it all out.
Have they given you and your son any carb counting training? You really need some. At the very least buy a carb counting book to refer to. You also need to retest his BG 2 hours or so after his food and insulin to see if the bolus given has been enough to return his BG to the pre-meal level - that's how you know if the ratio was correct or not, although obviously intensive exercise, illness etc can all have an effect. To give you an idea, my daughter's ratio (she is 14) is 3 units insulin to 10grams carbohydrate, but everyone will be different, so your son will almost certainly have a different ratio. I wouldn't try changing his insulin until you've done lots of data collecting (your spreadsheet sounds great) and discovered how close he's getting to bringing his BG level down to the pre-meal level 2 hours later - then talk to his DSN or consultant, armed with that info.
You are right, though, it is going to be up to him to carb count for himself, you cannot always be there, and if it's not done properly it causes problems. What sort of pump is he getting? Hopefully one with a built in 'wizard bolus' that can calculate his 'insulin on board', that is, the insulin still working from the last time. I say this because my daughter's worst hypos have happened as a result of insulin 'stacking', when we have undersetimated the lingering effects of the previous boluses and it's all caught up with her in the night and she's convulsed etc. As you say, scary! Her pump does not have the wizard bolus, we are trying to get her one that does at the moment.
I would recommend that you read 'Pumping Insulin' by John Walsh (try Amazon), it's very informative and known as the pumper's bible!
Sorry if I've waffled on and told you lots of stuff you already know! If you have any other questions, though, ask away and I'll do my best to help. There are a few other pumpers on the forum too who will probably have some good tips for you, esp about the exercise.
Sue