I'll continue testing and fill out the form when I feel like I have tried enough.
Here are two things I found today:
Setup on this test: ML on empty SD card. 4 GB CF card used for recording images/movies.
Minor display bug. The GB remaining (top right corner) does not refresh properly. It doesn't appear to erase the previous value before writing the new value. When you go to the ML menu and come back, the screen refresh cleans this up so that the GB is not messed up (i.e., it displays properly). See screen capture here:
https://picasaweb.google.com/lh/photo/gtRb7lAR1hphpAmeVO8Eus6bkbuOKDnQM31wDLF3lbE?feat=directlinkPossible error-inducing feature. This happened to the recording that I was doing while trying to capture the image referenced above. It was tricky, as I had to time it so that the GB remaining would change after I started the screen capture timer, but before the timer elapsed. It took several tries. I believe this is relevant, as you'll see. I let the CF card fill up by continuing to record. When the card filled up on this round, I got Canon error "Err 04 / Cannot save images because Card1 is full. / Replace Card1." To be clear, this did not require a battery pull. The .DAT file remained on the card, but the associated .mov file was blank. The ML debugging log (reported on screen to be writing) was also empty - it was there, just 0 KB. I tried to replicate with both no ML and ML and could not... until I tried the screen capture during recording.
My hypothesis is that the Canon firmware notes space remaining at the beginning of recording and subtracts off the recording size from this, stopping the recording in time to convert the .DAT file to .mov. The screen captures (I did three or four) caused the card to be unexpectedly full before the Canon FW could stop the recording and convert as normal. My own view is that I'm not sure that it is worth trying to fix this with anything other than a warning not to do a screen capture if you plan on filling up the card (perhaps this warning already exists and I just haven't seen it!).