OH NO! Since you mentioned the uneven seal on your lense I had to go check all of my lights and noticed this issue on my protac 2AA. I tried pushing it in with a thin guitar pick and it seems to have helped but I really hope i don't have the same water issues. I've given it a "bath" before with no issue but never really submerged it. I guess I don't plan on swimming with it ( which would be inadvisable anyway) so as long as it keeps rain out I should be ok... Hopefully.
From my experience, the gasket is supposed to be exposed where the lens & bezel meet. If you look at pics online, all the detail pics show the gasket visible, not tucked in.
I exceeded the recommended IPX Rating of 1 Meter 30 Minutes. I believe this is the "minimum" with room for production fluctuations. I doubt you would have any issue with it outside of swimming / submerging. So, if you really have no reason to submerge it, I wouldn't sweat it. How old is your light out of curiosity? The seal on my 2L was simply pinched on 2 sides were the water entered. On all other SL's I've tested the lens seal was great to perfectly even and you could feel it with a small screwdriver around the inner diameter of the bezel, total submarines with 0 issues greatly exceeding the IPX7 rating. The 2L I have now I get metal rub on 2 spots with a mini flat head driver. The seals on the smaller lights are much harder to see than say a PolyTac. Although, on the ProTac 1 AAA the lens gasket is a beast. Like I said, Im a stickler for reliability and if I thought SL was a dead end...well read my posts. I simply would not pursue them further.
All things considered, in my searching, I have seen some seriously beat up ProTacs / Streamlights online - some used as window breakers, hammers, LEO duty, all the ano worn off, mounting non mountable lights for extended periods.... and every kind of war story you could think of. All around excellent beater lights, which is exactly what I want, but I need that waterproofing for my application.
This is a great example of the "numbers" argument, only it's actually true this time. "Well there are thousands of XXXFires out in the field so you'll get a few lemons". I have seen more StreamLights than any other light on the net for professional applications X 100, and the complaints are far and few in between. Much more positive than negative feedback.
I will be contacting SL tomorrow via phone. I will update.