Good discussion. Although I wasn't able to contribute to why the bottle weirded out, here are my comments about your recipe.
As I long-time member of a liquid soap making group, 100% olive oil castile is one of the most challenging to make. It takes a long time to trace (45 minutes for me) and a long time to cook (3-9 hours on average; 10 hours for me the first time) until it tests neutral for lye excess.
TIPS:
Be sure your SB has a stainless steel shaft... the high heat of making LS can melt plastic.
Because OO has "unsaponifiables" you were correct to use 0% SF and 90% KOH. The thing to keep in mind though, is, once you know your KOH amount, you need that number X 3 for your water amount to make the lye solution -- due to evaporation during the long cook. There is a place on SoapCalc.net where you can enter 3:1
Water to Lye Ratio
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Dilution: While 100% coconut oil and more balanced formulas will dilute nicely at 40% soap to 60% dilution water, the recommended dilution for 100% OO is 15% Soap to 85% water. This results in thin soap but with excellent lather and cleansing properties. You will then need to thicken with brine solution (or thickener of choice).
Viscosity is, of course, a matter of preference. But the high viscosity of your finished soap means that a lot of it goes down the drain and it takes longer to rinse off. My recommendation is to take a portion of the soap, say 100 grams, and try the 15 grams to 85 grams ratio to see how you like it. I think you will be surprised at the feel of the lather and how well it cleans. I know I was! LOL
There's good info plus Tips & Tricks about making liquid soap in the link below. Faith also has a tutorial on making 100% OO using the glycerin method (which is what I do), but it is an advanced technique, dangerous due to the high heat of the lye solution, so I don't recommend trying it until you have a few more batches under your belt.
http://alaiynab.blogspot.com/search/label/tutorial
HAPPY SOAPING!
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