I agree with Pepsi. Replace the top with either brass or copper flat stock, and use brass barbs and solder it all on. You can get 2 inch wide brass flat stock at Ace Harware. I have experimented enough with Plexi and Lexan tops to know that I would never put a water block with a plastic top in my computer. I was thinking of buying a Gemini, but only if Peter would make me one with a copper top and metal barbs. I would even pay extra for it. Now the DD Maze 3 will have a plastic top. I think we will hear a lot more stories like this one until the plastic top craze is over. Because after the hose comes off the water block, you only have a few inches until the case side. So, you are making a bend in the tubing very close to the barbs, and with nylon barbs in threaded plastic, the side stress on the barbs will eventually cause problems.
Just my .02
Mustangman, just out of curiosity. During your 24 hr leak test, was the tubing coming straight off the water block with no bend near the barbs, like a bench test outside the computer, then when installed in the computer was there now a bend in the tubing close to the water block? Also, were you using Vinyl tubing or Silicone tubing? Silicone tubing is flexible enough that you can make a bend without causing too much side stress on the barb. You have to be real careful how you route vinyl tubing, it can put a lot of stress on not only your barbs, but also the entire water block. I have seen vinyl tubing put so much stress on a water block, that the WB wouldn't sit flat on the cpu die.
Blah, Blah. Sorry I was so windy.
Pudge