> Anyone ever have a failure like this?
This is very, very rare as far as I know.
Sometimes people have a problem getting the canister to mate with the stove - that happens in very cold conditions mainly. Not sure why.
> Examining the bad bottle I see the o-ring in the orifice is chewed up. I wonder if a bit got shoved down and is clogging it.
Would you be able to send me a close-up picture of this? My email is email@example.com, and I am the Stoves Editor here.
The 'O-ring' bit you are referring to is actually a neoprene washer bonded to the metal. The red plug in the middle seals against it.
If you take the canister OUTSIDE and give the red plug a poke with a BLUNT object, does any gas come out? But be VERY carefully if you try this - NO flames!