The third round tie was seen as the perfect way for the Hammers to forget about the ruling in the Carlos Tevez affair, which could cost them £30million by Sheffield United's estimation.
However, Aidy Boothroyd's side belied their place in the bottom half of the Championship.
The winner in the 70th minute was bizarre but they are used to that at Vicarage Road after Reading's phantom strike at the weekend.
After conceding that infamous goal against Reading at the weekend, Peter Walton was the high-profile late replacement for Keith Stroud as referee.
Watford may have been puzzled at the decision to give Stuart Attwell a Premier League game as a fourth official this weekend after his performance at the weekend, and giving Walton the tie gave them reason to be concerned as well.
Walton gave a penalty against Boothroyd's men two years ago when the ball had hit Chris Powell's head, although his blunder was not in the same scale as Attwell's and his assistant Nigel Bannister.
Half the crowd thought Lionel Ainsworth had given the hosts the lead in the 12th minute when his drive crashed into the side-netting but Walton correctly awarded a goal-kick.
It was closer to being a legitimate strike compared to Reading's `goal' - but lightning was not going to strike twice at the same ground within four days.
Ainsworth's effort was part of a lively start from the hosts. Ross Jenkins had a diving header that dropped wide of the post and Ainsworth also lobbed over Jan Lastuvka in the 14th minute and the Czech goalkeeper, making his debut, peddled back to tip over.
Freddie Sears was making the running for the visitors and he cleared the angle of crossbar and post with a drive, then Jordan Parkes panicked and almost headed a clearance past his own goalkeeper.
As the Hammers eased themselves into the game, Scott Loach was required twice to keep the score level.
Luis Boa Morte's effort from the edge of the area was heading for the top corner until it was tipped over, then David Di Michele's reverse pass sent Mark Noble through, with Loach parrying again.
Boothroyd's side were rubbing shoulders with Premier League heavyweights two seasons ago and they showed no fear as they finished the first half strongly.
Ainsworth went close again, drilling across the face of goal. Lastuvka was also required to save twice from Tommy Smith, the first after a flowing move that ended with Will Hoskins backheeling into his path.
Di Michele had sight of goal at the near post after the break but the hosts hustled him off the ball at the cost of just a corner.
Lastuvka was busier than Loach at the other end. He saved a powerful drive from Parkes before leaping to his right to stop Smith's header from Lee Williamson's cross from the left.
Lastuvka's good work was undone with 20 minutes remaining. After Walton awarded a questionable handball against Walter Lopez, Williamson swung over the free-kick from the right, the goalkeeper dived over the dipping cross, with the ball hitting Mullins and trickling over the line.
Jay DeMerit was injured and hobbled down the tunnel with five minutes to go, leaving Watford with 10 men - but they held on to inflict a first defeat for Hammers boss Gianfranco Zola.
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