well this just seems to be another example of cheaply made items....but unfortunately the prices are not reflective of their workmanship..... I would definitely follow up with some agency about the danger in using this product....better business bureau, underwriters lab, consumers report and everyone else I could think of........I wonder if this happenedf to "old" irons??? I don't have any R irons.....GE and B&D are mfgrs of choice for me.......so far so good, but who knows when these will also do something strange.....