Well, this is interesting to say the least. I've never seen this type of reaction before. Being that light unit was bought from HC, I have no doubt it is one of mine.
I would like to know if any smelly jelly or butt juice was used with this setup, how it was stored, where it was stored, for how long and what was the light unit used with?.. what brand and model lure?...was this stored where fuel or fumes or any other chemicals could have made contact with it?...age of light unit, age of lure..in direct sunlight..
Knowing all of these and having the light unit in hand would be of great help. I can test the resin of the light unit to see what affected it like this.
As for the light unit being difficult to move from one model lure body to another, as Springfever indicated, it is best to use a lube. The reason being that the light unit and the lure body both have smooth surfaces and just like with two pieces of smooth materials, anytime water is introduced, it creates a very tight seal. To help alleviate this, we are planning some changes to the resin molds to give a bit of a rougher {airiated} surface so the sealing effect is eliminated or at the very least, reduced.
While situations such as this are unfortunate, keep in mind that I cannot possibly know each and every event that could arise with the many varied lure compounds, lines, scent oils, exposures and storage habits of everyone who uses the products. Through events such as this, more is learned and corrective measures taken. Like any other product, evolution must take place to keep an item user friendly and reliable as well adaptable to the many uses the item will see.
Seafever, I will be happy to buy the light unit/lure from you so a proper investigation can take place or, if you wish, I will replace the light unit and lure-whichever you choose. You have my phone number, just give me a call.
Thank you,
Michael a/k/a "Salty-dog"
