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4 have flaked out on me in this manner. I've seen some water in the battery compartment on two of them, so you might be right about not cranking the door down tight enough as I'm pretty sure both of those have come after battery changes. The other 2 had dry battery compartments, so the theory is the rubber seal over the on/off switch let some water in.
I keep buying replacements because I haven't found anything better; I like the fact that with the red lens down, you don't have to cycle through a white light to get to night-vision-saving red.
These days, once one flakes out and I can get it operating again, I retire it from the surf. I have a couple around the house I use for rod building and epoxying lures.
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