Thank you very much for this very informative post, Will Wiggle.
I have bought the same cover (irex deluxe) , for the exact same reason that you did, thinking like you that such very expensive equipment should have the maximum protection.
A couple of months ago, I realized there was a little blister on the right edge of my ilaid screen, and was thinking that it was probably a manufacturing imperfection, even if I did not notice that blister earlier, when I initially bought my iliad.
After your post I tried to look at my iliad very closely, and BINGO!!! the blister is exactly located where the popper stud is located when it is between the cover and the screen...
I sincerely think that irex should do something about this, obviously their Deluxe cover despite the very high price has a big flaw. I hope that they will remain professional, honest and do something about that. It is their cover, so they SHOULD.
Please let me know what they will respond to you. I will write to them from my part as well, so they will know that this is not an isolated incident and that they should do something about their mistake.
Thank you,
Dabon.