one more question. i made up a starter by running off approx 1 litre of the wort from the cube around 30 minutes after it being in there, so it was still piping hot. i then cooled this down in its own sanitised "starter bottle" (3 litre bottle fitted with airlock etc. the yeast (wyeast 3944) took to the wort and it's now sitting in the fridge awaiting it's turn to be pitched.
should this yeast be ok, considering it came from that wort - would the wort have become infected sometime today when the wort temp dropped to around the 30c mark?
If you filled your cube with boiling hot wort and are sure there were no air pockets inside, and made sure all the surfaces got the boiling treatment, and you didn't open it, then its difficult for me to understand how any infection could have gotten in there! I mean the thing was sealed with boiling liquid, right?
I just don't see how an infection could have gotten in. Would have to be a pretty damn funky infection to be able to survive your sanitising regime of bleach and napisan, then boiling hot wort.
(small point, but I would have used the napisan first, then the bleach, then rinse)
Your collection method for the starter was to just open a tap at the bottom and collect some wort while it was still hot, right? I don't see how that could introduce an infection, unless the wort was below about 60C and you managed to suck up a bit of air in the process of opening the tap.
BTW, did you check your tap to make sure there wasn't any gunk in it, or the threads or anything like that?
You mentioned you managed to get 3 litres for the starter. That sounds like a lot to bleed off from a 20 litre container, without having air being sucked into the container. Did you squeeze the container to get the wort out?
Apart from the fact that I have *NO* idea how an infection could have gotten in there, given your regime for looking after the wort, if there was an infection, and your container puffed up, the infection is in the container, and so it will also be in your starter.
When your container puffed up, did you have a smell of the gas inside it (there was gas inside it, right?)? You should. Did it smell like CO2 or something else. This could give you a clue as to the type of infection.
For the starter, as I said, I reckon any infection will be in there as well. So if you chucked out our main wort without smelling or tasting it (wheres the slap-on-the-wrist emoticon?). Give your starter a smell now. If it smells fine, keep it sanitary and leave it for a week or two, and wach for any signs of infection, give it a smell etc. Do this at the same temp as your wort was.
If you wanage to get through a couple of weeks with no obvious problems with the starter then my best bet is that you did not have an infection in the first place, but I can't explain why the wort container puffed up.
Apologies for the excessive length, but thinking out loud here.
Berp.