I removed my egg and put it on the table for better use as the frame was about 1/8 inch closer at the top and bottom the middle of the arch. Tried everything, even smoothing, but still the same problem. As a result, I just used the original frame with a new screen and door. I removed the old silicone and used J&B 500 grade silicone when I reinstalled and let it dry overnight. Looking forward to grilling later today with my new air vent. If you have a large BGE it's highly recommended that you save some money and just get the screen - as this is a 5 minute install as opposed to this one which because I removed the old one took around 3 hours lasted - basically cleaning and stripping the screen flint, and also used this as an opportunity to clean the nest. I could probably get this working with enough silicon, but have chosen not to settle for imperfection.
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