James,

That's pretty amazing, bet it's the drivers side. After having those exact
same experiences and before reinstalling the replacement lens, took a
business card as a gauge and in various spots, slipped it between the van
body and the plastic PZ housing. After pressing the housing in place (by
hand) would try to pull the card out. Found a few irregular areas on the
housing that when screwed down, created to much stress on the lens and
fastener hole. Used the dremmel tool with mini sanding drum to cleanup the
irregular spots. Epoxyed small washer on TOP of distorted/torn fastener hole.

Followed Michael Sullivan's wiring diagram and all is satisfactory.
http://www.hsdesign.com/vanagon/foglight_wiring.html

Replacement lens can be had by calling Steve @ 1552 Design 941-343-0477
around $80.00

In conclusion, Projektzwo lights are a great design and provide excellent
lighting but for $325.00 a bit cheesy in quality/fitting

Roger.