Well... I had a discussion with BRS and the guy I spoke to was quite helpful but claimed to have never heard of this problem. It was said the issue would be pushed up the ladder to Ryan and others. Ultimately they don't have any lights right now and expecting end of month. My account was annotated as likely to return for replacement. I think the only thing I'm concerned about is the typical send us the lights and we will send replacements policy. I don't have backup lights at the moment and I'm not going to leave my tank dark for perhaps days. Well I do but I'm not going to the hassle of reconfiguring the top of my tank and dragging out a massive 6ft MH/T5 fixture and hooking it up. No definitive answer but there seemed to be the possibility of CC secured cross shipping or maybe free overnight replacement shipped when UPS scans the returned package leaving things dark just a day. In any case I would really like to see BRS step up and issue an official stance on this. I've used them for years and spent many thousands, as have many others, and would expect nothing less.
In reality though while I want my lights replaced I don't think I want it until the problem is resolved with improved/redesigned parts. Unfortunately I suspect that might be something as half done as the same part with a couple added rubber washers. Worst case I will repair them myself.
And BTW not to judge but Torx has been around 35+ years and a pretty basic tool that's usually part of even a basic bit set. Then again I have more tools than God