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@BarrieEngland: Exactly. For example you have "Everest South Summit". That's why I'm saying that in practice, the distinction between these two words is really blurred and can be used interchangeably.
Perfect. Your first example clearly shows how the negativity is removed from the sentence. I agree with you that it hardly conveys a message close to almost perfect. So, as far as my question is concerned, less than perfect, as a phrase, always carries a hint of sarcasm.
@Chris: I think there's still a hint of sarcasm here, too, and agree with Luke. Maybe not toward the to-be pilot guy, but toward his sense of sight. To me, without the sarcasm, saying that his vision is "less than perfect" would suggest that "nothing is perfect, so is your vision. so it's normal", which is not the intent of the speaker at all.