Originally Posted by David Hettel
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Jake is not the only one experiencing this, nor is he the first. Another user is on his fifth device. Both are exchanging the complete system, and each of the eight units are all new. Also two 4000 mAh batteries have failed to date. 
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Do we know precisely what hardware component has failed in each case? What part of the overall power system "decides" how/when to send current? What actually reports how much power is available? Is it the battery that reports it's available power to the iPAQ or the iPAQ that queries the battery? I'm wondering which part has failed. For example, it would be informative (to me, at least) to have someone try a non-HP battery in the iPAQ to determine if whether the battery or the core device is the failing component. Perhaps someone with an iPAQ 4700 battery or third party battery could slap one in and see if the problem repeats. Conversely, it would be equally interesting to see what happens if someone were to put the 210's battery into either another 210 that is over 2 months old and hasn't experienced this problem to see if the problem follows the battery.
I also wonder if it has anything to do with the headphone jack leaving a gaping hole exposed to the battery compartment. Maybe it's a stretch, but if someone lived in a high-humidity location, is it possible that condensation could get into the battery compartment and cause a short? I have the hole sealed off with some electrical tape, but maybe others don't?
No matter what, this is indeed a disturbing problem, and I wish I knew portion of the hardware is the root cause.