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This is how we will ship the hood and tie down knobs from now on. Thanks for the input.
Can't do anything about international costs. The way of the world.
The gaps are part of the design. The magnesium case of the Odyssey features four small tabs that extend forward about one millimeter from the front surface of the OLED screen. They are there as a point of protection should someone lay an Odyseey down on a surface face down. They are four little legs to raise the screen off the surface so that it doesn't get scratched. They were placed close to the corners to make the platform as stable as possible, but unfortunately this also means that they are located right next to where the living hinge must be. If you look at the lower hinge on each side of the hood you can see where the material is stepped back to allow for these tabs. There are another set of step backs near the tip ends of the hood. The way the liquid material is injected into the mold meant that the hinge needed to maintain that same profile, so we wind up with a small one millimeter step back on either side.
Actually getting any light onto the screen is very difficult. Try taking a flashlight (Brits call it a torch, correct?) and shining it in through the gap. There is a very small angle at which light can come in and hit the screen. And because of the wraparound nature of the monitor edge of the hood, there is no way to have this light shine back ino the operator's eye.
So yes, in theory it is possible to get a light leak but in practice it is extremely rare and fairly minor.
Next time (as in the next product we ever make with a monitor on it) I'll ask for the tabs to be located a few millimeters away so we can eliminate this issue. It's our first monitor and sun hood design.