that is weird. I design parts of aircraft engines and we always use "race track" seals. This is just a groove around the housing to cover and it is like a 0.100 width & deep with small rads in the corners to prevent maring of the seal.
The o-ring material is cut to length and pushing into groove. It compresses like 20% of it when it is mates and torqued. Since the o-ring seal is very large you can have a larger profile when maching. When the machines today I do not think it is because of tolerances. More a crappy design if you have problems. Our designs go through a lot more testing then cars or diesel engines. O-rings are the way to go if you select the correct material from the start.
The o-ring material is cut to length and pushing into groove. It compresses like 20% of it when it is mates and torqued. Since the o-ring seal is very large you can have a larger profile when maching. When the machines today I do not think it is because of tolerances. More a crappy design if you have problems. Our designs go through a lot more testing then cars or diesel engines. O-rings are the way to go if you select the correct material from the start.