1. The CD was a PATHETIC chip.. a chip that was introduced but wasn't the best (anywhere near, in-fact). The CD models are the hottest MBP from what I have experienced. I have to put up with constant 80°C (176°F) temperatures, I am guessing that you do not have to put up with temperatures that get near 90°C>95°C (194°F>203°F). If you have to return your Penryn because the side has started "buldging" then you must have a dodgy model. I dare say it will be your only problem Mac... Apple has a slight fault-rate, from what I can gather from your arguement every single Mac laptop has a problem.
2. I checked with dad, and no they do not make extensions to their 3 year Apple Care. I think that is basically because if nothing has broken in that 3 year period then it should last you a whole lifetime (unless you drop it or something). Besides, who wants to put a warranty on a 3 year old computer???? If it breaks down then its not even going to be worth much, may as well go buy something new and up to date..
3. You must clearly have a poor thermal paste job if you are getting excessive heat on a Penryn MBP. They do not run hot! My Gf's will hit 40°C (104°F) when doing nothing, and 60°C-65°C (140°F-149°F) when under load. If you are getting hotter than that, then yea you have a bad thermal paste job (I take it you've already gathered that). If you are such an expert on thermal paste, reapply it yourself!! Don't criticise other people for doing their job (whether it's good or bad), they might of had a bad day or something (we ALL have those).
4. To be frank, I don't think you are very nice (tit for tat). I will explain my situation. I am 18 years old, doing an IT degree in Network and security. You probably have 40 years of experience on me, so come back to me then.
Fans are given an "average" run time based on tests. Not every fan will fit exactly to that run time, they will vary determined by a number of factors which you have said. So far, the life span of my fans seems to be going quite well. They are running as if they are new, I bet if I opened the case they would need a clean. Other than that they are quiet and effective (well, as effective as they can be on the CD).
5. You find me any Penryn related heat problems and show me then we can talk about that.
6. You make me laugh, my Gf's laptop will be lasting a nice 5 years at the least (We are even game enough to not get warranty)

.
Probably on his 1 mac lappy experience... no idea on the ratio..