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Sounds like a dud charger.
That metal "doo-dad" is the voltage regulator and while they are suppose to get hot (regulates the voltage by emitting the excess as heat) it shouldn't melt through any wires.
I picked up one of the Radio Shack 1000mah versions of what you got and so far it's worked out fairly well.
Once you release the magic blue smoke, you're pretty well hosed. :) Looks like a new charger is in order. I'd say give Jon a call and see if they can RMA you one.
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