call customer relations, ask for them when talking to a apple care rep on the phone.
they would have replaced this all ready, they do not screw around with serious stuff like this.
just call and say...this thing blew up...smoke black marks.
enough said.
My service provider took pictures of it and sent it to Engineering. Engineering said the adapter looks to have been accidentally damaged, possibly by water or a surge. The pictures my service center took are the ones I added to the first post. I think they're assuming a surge based on the melting on the plug of the extension cord.
Customer relations was closed when I spoke with tech support so I'm calling again tomorrow.
Pretty pissed already at this point. Non stop issues since October. Its my 4th service request in 4 months.