Anyone else had this happen?

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considering that you have adapted/modified headlights I'm assuming that they weren't re-sealed correctly. Firstly I would ensure that all the covers at the rear of the unit are on tightly, and if so then look to re-seal. I found this video for you as a starter:  Recently bought a 2007 RRS HSE TDV6 for a Pimp-My-Ride-Project.
DONE: Meduza front bumper, AB rear bumper, AB tailpipes, calipers repainted, rear upper tailgate upgrade, side steps, AB front grille, AB side vents, rear LED lights, clear side repeaters, integrated daytime running lights, LED headlights.
TO DO: color code sills and pillars.

Yes they are modified, but these were done in 2012 with no issues since. This has just literally appeared in the last 3 days. I've seen a few vids on YT so i'm going to try source some Butyl Rubber strip and re seal them. Apart from Amazon I can't seem to find any stockists.

yes that is very strange how water has entered. i take it that you've checked the lens for any small damage, stone chip or bump. It's probably best to eliminate these areas first, before the re-seal. I've also had a look around for a sealant but with no luck  Recently bought a 2007 RRS HSE TDV6 for a Pimp-My-Ride-Project.
DONE: Meduza front bumper, AB rear bumper, AB tailpipes, calipers repainted, rear upper tailgate upgrade, side steps, AB front grille, AB side vents, rear LED lights, clear side repeaters, integrated daytime running lights, LED headlights.
TO DO: color code sills and pillars.

Got the headlight off, removed the bulbs blown hot air through them this has cleared the fogging, all the breather pipes are clear, no sign of damage anywhere all clips are in place so looks like it's definitely the seal. Going to order from Amazon and then I'm going to have to remove the lense to clean inside as them dry water marks will stop me from sleeping.lol