On Friday I went diving with friends and set up my housing as usual (Seacam 5D2 c/w 100mm usm macro). I went through my pre-dive checks on the camera and everything appeared ok. Fortunately I'm the sort of person who still checks the housing as I descend and on this dive it was just as well, as by 4m the water detection alarm was flashing and beeping (I hold the housing horizontal whilst descending). Needless to say I bailed out and headed to the surface with the housing held with the port downwards (on the basis that a replacement lens would be cheaper that the camera body) but by the time I'd surfaced the water had reached the front element of the lens. I inflated everything and held the housing as far out of the water with the port downwards as I could until I reached shore. As soon as possible (I was still fully kitted) the housing was undone and water poured out.
As I took everything to pieces I carefully checked to see what might have been wrong and realised that the port did not need much rotation to remove it - it had quite simply not been rotated right down until it reached its normal stop, and as a consequence had not seated the 'O' ring properly. I have only myself to blame - stupidity on the part of the user! It is of course possible that I had rotated it fully and that it had become undone between assembly and diving, but this is in all honesty very unlikely as considerable force would have been required for this to happen. After I got home I stripped out the housing's electrics and washed it and the port thoroughly before drying everything with the aid of Silica gel and a dehumidifier. Fortunately both camera and lens, whilst damp seem to have suffered no ill effects and are happily working again after very careful cleaning and drying (tissues, cotton buds, etc.), with no sign of actual water ingress into either. After rebuilding the housing I tested it in fresh water to ~20m and it is fine - no leaks - so I'm confident that my conclusion of user error was correct.
So the moral of this tale is that as in the vast majority of flooding cases that I have ever seen, it was the user who was to blame. I now have another pre-dive camera check to build into my routine and hope that my floods occur at the 15 year intervals that this (my second - the last was a Nikon F801 which was totaled) indicates. I already knew that absolute methodical assembly of a housing is essential for every time it is used and this has been thoroughly reinforced.