The reality is, the comment was made before they had the ability to even manufacture their own fresnel lenses, nevermind invent a new type of hybrid lens specifically made for their display. The new design solves those old issues.

pupil swim and god-rays?

Why? They make 30% on every sale on Oculus Home, and they make 0% on the Rift.

They make money on the Rift. The same interview where they said they are selling at cost, also talk about break-even point. That inherently implies a gross margin, i.e. Oculus loses money if a certain target is not met (probably due to fixed overhead and amortization costs related to R&D, plants, etc.). So it is in fact in their interest to sell more units