DigiQ Adapter Mod

Couldn't decide on a title.  "Am I really OCD" and "A solution looking for a problem" seemed to fit also.

The adapter for the DigiQ is flat and the intake vent is curved, so it's a hassle getting the two to mated up.  Lots of pushing and shoving. I have my large egg in a nest, so can't slide the adapter in from the side with the long side vertical ... I have to use the steel clip.  @TheShaytoon showed how he gently bent his to fit, but the folded steel clip is extremely stiff and doesn't lend itself easily to being bent.  Decided to do a little experimenting and here is the result:

I measured the diameter of my large egg at the lower vent and came up with 16 inches as a compromise between the diameter at the top and bottom of the vent.  Then, knowing that metals spring back a little after being bent, the diameter was reduced to 75% of the actual diameter ... simple WAG.  Cut a small rectangle of wood, drew a 12 inch diameter curve on it, and cut the curve out on the band saw.  Here's the fixture shown with the adapter already shaped:



Here is how the fixture was positioned on the adapter ... it was positioned like this, placed in a vise, and clamped tight.  Applied to both the top and the bottom of the adapter plate:



Here's a quick picture of the result on a tablet to show how much and how smoothly the adapter is curved:



You'll notice that the steel clip is also curved, so that now it'll slide easily back-and-forth across the top of the adapter.  The adapter now slips easily into the lower vent and the air seal looks to be a little better..

I only have the one egg, so no problems with modifying the adapter (they're only $25) to fit.  YMMV.  Also, if I had to do it again, I'd measure the diameter at the bottom of the vent and make the fixture based on that dimension ... the steel clip has more spring back than the stainless.