1) I have taken about every kind of 3rd party battery apart and have rebuilt them myself. Just order the correct size cells and voltages, resolder them together, and close the housing.
2) Batteries that warp and overheat are commonly results of the CHARGING system coupled with the poor battery design. So if you have a problem with an aftermarket LP-E4, you will most likely see it while it is in the charger, not while it is in the body, but it can happen if the unit using the battery short circuits somewhere, and the battery allows a fast drain, resulting in overheating and whatever happens afterwards.
3) So much good luck with Sterlingtek, Accstation, and the Delkins/Black Diamonds, etc, so the tried and true aftermarket batteries are safe and most of the time work better. The caveat here is to buy from a reputable seller and see what the history is of the batteries in question. Unfortunately, this is a new battery, no history (yet).
4) Funny you mention some of these batteries, most of the ones having problems were name-brand laptop batteries. Other aftermarket ones have issues too, but the most hear of were name-brands.
Finally, we are all grown ups ready to take on the responsibilities of buying and trying these out, perfectly knowing the risks, so please don't hijack my thread. There will be folks that try it, they will report back, and we start to determine which aftermarket ones work fine. Just because I bought a $3K MKIII, doesn't mean I have $115 just sitting around to buy a spare battery, nor am I a brand-elitist. I love competition, it is good for all of us, and I hope the aftermarket ones take off, it will bring down the Canon ones over time.
A littel off the subject but didn't Dell have a HUGE recall on their laptop batteries 



