I also have slight light leakage below the buttons. I'm usually very anal about any defects, no matter how small, but since I really love this phone, I was willing to overlook this issue. However, today at the grocery store, I noticed that my EVO has slight separation from the screen on the right side, in the same area as the volume buttons. I carefully inspected the phone when it arrived and have done so daily since receiving it, so this just happened. I can only assume it will get worse, despite "babying" this device.
I really don't want to go back to AT&T and my iPhone. I'm getting great service with Sprint and much faster 3G speeds. I don't know if I should cancel with Sprint, exchange it, or wait until later on down the line to use the warranty/insurance when it is (hopefully) more likely that HTC has resolved these issues.