Didn’t the early ProII ss hub suffer from body fractures so the design got changed a bit? As per this thread from 2007:-
http://www.observedtrials.net/vb/f3/strong-ss-specific-hub-experiences-32776/

Wonder if your’s is an early hub and they changed the seal size at the same time?

I too find it frustrating that my ProII ss hub needs much more attention than a 1996 XC hub that is still in regular use….. That one has a proper radial seal instead of the crappy axial contact plastic ring they use now (I’ve found Hope ignore any comments / suggestions like this and just quietly and efficiently send free replacement parts ready to fail again in another 6 months).

My wifes XC Ti hub has the screw on ring and spider for the disc on her bike and is still running sweet.

ahhh (wistful look into distance), I still have 2 pairs of them in regular use, love those hubs…

Well, just spoken to Nick and the early hubs they did use a smaller seal. So i wasnt imagining it !!. He has scoured the place and found one. It is being posted. Thanks for the help everyone. i will measure the new one with the old ( potentially worn) one and see if it is worn. He says that if it still lets water in , in the way i described, then a new freehub is possibly the way.

result!

and now we’ve learnt something too, to keep an eye out for the early ones. Hopefully new seal will sort out your problems!