Finally got to the bottom of this I will report it for future reference of any one in a similar situation with the sharp well defined line.
It is the rotating back light seal, two strips top and bottom 7mm x 95mm.
I noticed a small amount of movement in the back where it connects to the rotating back, I suspect that over time the rotating back seal has worn and is allowing an ever so slight amount of movement when the dark slide from the back is inserted, particularly if not lined up 100%. That is probably why its intermittent, sometimes you drop lucky with the darkslide insertion.
After I noticed the slight "play" I checked the spec and it was for 1.5mm foam so I used 2mm to provide a more effective seal and more resistance to the torque when inserting the darkslide. The flipping fasteners under the foam seal don't help, they stand ever so slightly proud thus the foam in that area gets worn faster.
Just developed a roll and checks out ok. Yaaaaaay !