I have done a fair amount of reading on CO2 systems, very few folks have experienced overpressure venting of the CO2 tank. In fact, my understanding is that the overpressure safety valve consists of a disc that ruptures at a certain pressure, releasing all of the contents...which sounds different than what Marlin is experiencing. Maybe something to do with his regulator?
Mine doesn't have a rupture disc, it is a standard CO2 bottle from a pop machine...I paid about 125ish IRRC for the bottle, regulator, hose and chuck on Ebay. The 20lb bottle, I bought off of Smiley on the Planet for 20 bucks, but it needs a hydro.