So, I'm coming to the end of my first year diving dry, and I just had my first seal "issue". Silicone seals on the round SiTech rings, total of about 10 dives on them I think.
Fortunately/Unfortunately (depending on your perspective) I wasn't the one diving the suit at the time. My wife decided that she wanted to give it a shot, and we were just in the pool, not in actual cold water when we discovered the leak. Her wrists are much smaller than mine, but I hadn't trimmed the seals at all. The neck seal (also silicone) seemed like it might be on the verge of being a little lose during the initial try-on, but generally seemed to fit ok, as did the wrists (no detectable gaps).
As soon as she got in the water, she felt wet on one arm. I re-checked the seal, and slid it up her arm a little to see if that would help. Since it was just pool time, she did the rest of the dive. Afterwards we dumped a lot of water out of the suit, so definitely a leak. So, her first time diving dry (well, 2nd if you count the brief DUI Demo that we did) wasn't so dry after all...
After we got home and hung stuff up, I took a look at the seals and found the source. There was a small hole (maybe 3/16") up near where the seal is held in by the ring. I've been diving the suit with the SiTech Glove Lock system in place most of the time, so this was sort of hidden up under the adaptor ring which I leave in place. Only when I started pulling and poking at the seal did I see the hole.
Hard to tell what root case was. It looked more like a tear and not just a thin area in the original casting. It's possible that it was pinched at some point when I was removing/installing it into the rings. Since I haven't dove it with wet hands since the first time or so, it may have been that way for some time.
With a little coaxing (as in doing the damn, that's a whole poke/prod/stretch) the tear did grow, but I was still able to don/doff the seal without it having a total blowout. That said, given the nature of silicone there's not much that would have worked to patch it up to save a dive really, but isn't that why we do the ring system anyway?
With a new set of seals on the way, I decided to turn it into a learning opportunity. With the stretchiness of Silicone, and reports that it will relax a little with use, I've never bothered to trim the seals at all. They've been comfortable enough as-is for the diving I do. No signs of blood flow issues to my hands or whatnot. With nothing to lose, I started cutting rings off the busted seal and trying it on. After just one ring I could feel an improvement in comfort. Took a second and it still felt good, but not as dramatic of an improvement in comfort. When I get the new seals, I just might be tempted to trim a bit, since comfortable or not, I suspect that having them fit better might lessen the chances of damaging them while going into or out of the seals. Then again, Wife may give it another shot and I don't want to take a chance on them being too big for her.
Side note: Anybody ordering these seals out of the UK for US delivery? Checking, it seems like they're a bunch cheaper over there, but with customs/shipping/transaction fees, it might equalize pretty quickly.