Stu/Danny - might be worth having that discussion offline rather than in this thread?
As for the original post, the design of the sump looks pretty good to me, I guess that either a weld wasnt quite right (seems unlikely having seen dougs welds first hand, I genuinely cant think of anyone I'd sooner trust near a welder TBH) or perhaps the material specs arent quite right to cope with the vibration or similar.
Real shame if these sumps arent upto the job as I know Doug cares a lot about people enjoying their cars etc.
Will be interesting to see what he says about it, although stepping onto PF to discuss it would be a pretty fruitless way to deal with it probably as no doubt 100 uninvolved people will just start jumping up and down and making claims he should stand on the entire cost of the engine etc, and it never works like that in reality, even cosworth refused to do that when their oil pumps killed people's engines.
Lets hope its just a couple of isolated failures out of all the ones sold and not indicative of an inherent problem given that so many people have been using them without a problem.