** So you were right in your first quote:
Thus our singular set \Sigma is defined by
\Sigma=\{x\in M|rank(df_x)=3\}. Outside of the singular set
the rank of the map f is 4. According to the work of Stingley (under
the supervisor Lawson), generic (stable) maps f:M->N between
homeomorphic 4-manifolds have only rank 3 singularities. **
That seems already much more logical to me.
**
But now we are in the standard situation: \alpha is not
invertible and we using the conjugate \alpha^* to define a
formal inverse via \beta_s. We don't see any problems in
this definition. But we know that this approach bothers you. **
No, you are still not in the standard situation : f still operates between two different base manifolds while \alpha does no such thing (so you are still working in the pull back bundle I described before). Now, consider two Riemannian metrics g and h on M and N respectively and assume that the connections you consider are metric compatible (wrt to g and h). Then, you have a canonically defined conjugate and there is no problem as far as I am concerned (I also stressed this point before, but you kept on insisting working at the level of connections and independently of any metric):
h_{f(x)}(df_x(v_x) , w_f(x) ) = g_x (v_x , (df_x)*(w_f(x)))
So you should add this subtlety too.
Ok, so now provide us with a real example - I agree now that it is well defined - which I did not see yet.

Note that such procedure can never produce COMPLEX curvatures as you once claimed.
However, my physical objections remain:
(a) \Sigma is a three dimensional surface, so where is the worldtube ?
(b) in the Lorentzian case, it seems to me that you have to put in by hand that \Sigma is spacelike wrt g
(c) your matter is a sitting duck, nothing changes to the curvature outside \Sigma : in particular there is no Weyl tensor in a Minkowski background. You might in the best case generate a ricci volume effect in ``space´´ but you still have to tell us what the *physical* space is (see (e))
(d) What is the dynamics of your function f - this is related in some way to (a).
(e) What is the relational context between different chumps of matter (in either different f's) ?
Anyway, that is enough for now.
Cheers,
Careful