I was thinking this as well. The inside of the cooler wouldn't be like hitting on concrete or something. What was the temp difference between the wort and water in cooler?/QUOTE]
There wasn't any water in the swamp cooler yet, it was dry. I really think i set it down to hard in the cooler, and i had an air tight stopper on the carboy, which may have caused some built up pressure. The wort should have been in the upper 70's in terms of temperature since i chill my wort before i bring it inside.
I went with the BB over plastic buckets because i only use primarys (no secondaries) and i have been warned that buckets are not good for long primaries due to potential air leaks. Not sure if that is true. I generally leave all my beers in the primary for 4 weeks.
NJTarHeel, i'm sorry to hear about your brother, truly tragic.