Regarding the lights. I just ordered new 64HD's from Marine Depot. The lights arrived super fast, but like yours they look like the casing has been opened, screw driver type marks between the seal and they do smell like you have eluded to. Nothing to do with WaterBox though as they get to you from the manufacturer, WB don't keep the lights on site. They ship separately.
Now in my case, they did ship from Marine Depot, but not their fault either. The issue with AI seems to be a lack of quality control and a lack of customer service, in my experience. I am currently waiting a "call" from AI to have my lights replaced. It's sad, because Ecotech and AI make superb products. They are just let down by the two things I mentioned. I truly wish, from the bottom of my heart they would fix that.