It's so had to tell from second hand information what to be concerned over when you don't know much about the person on the other end, the product's age, or how the item was used or abused. That said, I do have a degree of confidence in GreenLED.
GreenLED, the colors of the two EOS you've had to have repaired are blue and *what*, and can you offer any more details as to how the problems came about?
My first experience with a cracked Eos was the black unit. I had it as my bike helmet light, and it "simply" developed a crack in the battery compartment hinge. I say "simply" to imply that I didn't abuse the light/helmet in any way to cause that kind of damage. PT replaced that unit.
My second cracked Eos (blue) is actually the very first Eos I had (gift from jch79, maybe 2 years ago, IIRC), and it's the one I've used and abused most. It's my outdoors light, and I take it into the field often. Plus, it's the light my younger son uses to play with, so it's seen it's share of "fun times" with him. The light has been modded, dunken in water, dropped, scratched, etc. I just came back from an 8 week-long stint in the field and realized there's a hairline crack along on the top of the case. I *think* that comes from tightening the battery compartment screw too much, since the crack is right alongside where a brass "nut" is embedded into the light's case (which is where the batt compartment screw screws in). I've had that light get wet inside. At the time I thought it was poor o-ring lubing but now I'm thinking it might be the crack on the case...
My son uses another Eos (blue) on his helmet. He's considerably rougher on his gear than I, and isn't showing any cracks. I bought that headlamp a little after I got my other blue Eos.
I also have another Eos (grey/yellow), which I bought used off BST, over a year ago. It's another beater light, being used by whoever needs a light at home (and more recently by my youngest son as his "play" light). No cracks there either.
Hope that helps.
