It may be that from a PR perspective, it's simply worth every penny to offer their customers peace of mind. It is a lot of money to spend on a camera to have a problem like that. One that's vague in it's actual impact. And you're right, I don't think anyone has had the brass to test and see if the issue affects weather sealing.. (anyone want to volunteer?) Though, I'm sure Canon R&D did weather sealing tests before settling on the final design. Maybe it was simply a manufacturing problem after the fact.