I finally got the energy to replace my crusty old gasket with a nice new Nomex one on my large egg. That whole procedure went well (as far as I can tell). However, when reassembling the grill I wasn't able to get the top lid to line up precisely with the bottom. On the side where the handle is, the top lid comes down at least 1/8" inside the bottom.
What I found was as I was tightening the carriage bolt for the top band, that action was pulling the lid back toward the hinge. I'm thinking replacing both carriage bolts might do the trick, but I wanted to see if anyone had any advice. Also, I don't think 1/8" is really going to hurn anything, but if I can get it fully in line, I'd be happier.