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I had a fox rp23, serviced, sat for over a year without use, then on FIRST ride it blew just riding down the street (damper cavitation).
Seals need to be improved, or they've moved to a different supplier as I have 2x much older fox shocks that can sit for years, then just be put on a bike and just bloody work, no sticking seals etc! Backwards evolution in progress.
I'm refering to the seal head seal that the rebound rod runs through, it maybe that a sealhead maybe out of tolerance if it repeately leaks, we had one of these on some O.E rebas (I have noticed a difference in the quality of some components on O.E units) that even with higher spec seal still blew after a week or so (swapped to a custom tuned dual flow assembly)
The seal inside the rebound units spoon's refering to is a no replacable one as the hole assm. and rod is punched shut and you destroy the unit if you try and take it apart so it's a whole new unit.
EDIT Brickman, leak out the adjusters? the seals are constantly under pressure even when sat, the nitrogen charge being upto 500psi statically.
I'd be slightly careful with tight seals as they can get caught when installing and get 'nicked'/damaged, they may also affect the sensitivity of the fork is some cases.
As always there are better seals and seal materials but they're pretty exspensive even when bought in bulk.
OK, by way of an update. I'm really pleased to say that Chain Reaction dealt with my problem really well. Fork was returned to them via Collect Plus on the evening of 5th July and a brand new fork arrived with me yesterday morning. No quibble over cut steerer whatsoever. Fork now fitted and set up. Hopefully I'll get time to get out and test / fettle it later.