I must say that the only time I have had a problem was when the damn reset button seal broke (fat finger syndrome), got it taken care of and replaced and no problem since. Maybe 10k on it since the change.
That said I do know that many have had issues and for the life of me, this has been going on since 05. Have heard all kinds of so-called fixes that BD was workign on and know that some mods have been done. Still it seems the root cause is not getting taken care of as far as fogging goes.
Have no idea why either, since the man is Autometer who makes very good gages including some of the best marine gages out there. Most never have these issues, so either Autometer has come with a very bad design for BD or BD gave Autometer a bad design to start. Either way both are very good companies so it makes no sense why a simple thing as insuring the internal stay seal and fogging is out.
Maybe it is the plastic housing that allows the external elements to get inside.
Here is an idea for BD, if the plastic housing is cracking or breaking and allowing penetration, go to a cast metal or something. Pull a vacumn on the case to remove the air and mositure and then charge with a slight pressure on inert gas such as nitrogen.
Now that I said that, I wonder how hard (or maybe unrealistic it would be) to install a small shrader valve on the bottom, pull a small vacum, seal any leaks, and then shoot some nitrogen in at just something like 1 or 2 psig.
Just my 2 cents,
Alicat, by chance was one of the replacement after we ran that rain in WV last year. I did have a slight fog and dancing light shortly after that, but it cleared up and not since.
Best to all and safe riding.