Out of ideas! (dome/band issues continue...)

JLNC- I see your point on the top ring.  I have to admit though that with respect to the bands I often hear 3 (seemingly) contradictory instructions:
1)  seat the bottom band as far down as possible (ie against the ceramic lip)
2)  seat the top band as high as possible (ie against the top ceramic lip)
3)  ensure that the bands are evenly spaced all around

Perhaps I am missing something.  The spacing of the bands is predetermined by the hinge (see photo with tape measure at hinge).  If this spacing is to be maintained all around it would not be possible for the bands to be fully positioned against the ceramic stops.  My band spacing is as follows:
hinge/rear - 3/8"  (6/16")
right - 5/8"  (10/16")
left - 7/16"
front - 11/16" - roughly double the spacing at the hinge
This is close to what I would expect I guess - you can move the top band higher the farther you are from the (preset) hinge, but close to the preset hinge the spacing is a given.

I have not asked BGE for a new hinge (or any other hardware) specifically, but I have asked their advice.  They offered to send a new set of assembly instructions.    Mechanically speaking I have always considered myself decent.  I can swap out a garage door opener or washing machine timer/pump - even do a brake job on the family car in a pinch.  I suppose I fall somewhere in between "change the A/C filter" and "add a bed/bathroom in the attic with no permits and no contractors."  After 3-4 passes at getting this egg together, I should be able to figure it out.  So I tend to agree - albeit somewhat self-serving - that there may be some underlying hardware issue.  I know from replacing the seal that the ceramic lip is not perfectly flat.  There is a distinct hump in one section.  I may never get a "dollar bill test" to work properly.  If that were the only issue though I would be thrilled at this point!

I had similar issue with my large egg had to fight over a week and half with BGE Canada to get a replacement. They finally decided to send a replacement and it took five weeks to receive my replacement part after fighthing for over a week! Where's the customer service in that BGE Canada!!! I love my BGE a lot but BGE canada customer service is extremelly orible. I started a petion to send to the head office in the us about it and so far I have 12 people in Halifax area to sign and the issue they experience with BGE canada. Hopefully the US BGE office will act on this and give them a wake up call. Two weeks ago I was gone buy two new large egg and decided to go with Kamado Joe instead due to BGE lack of support for there customers in Canada. Kamado Joe customer service is beyond excellent and there grill are better built ( they actually fixed all the issues the egg has!) and they listen to there customer service! This is my two cents worth! 

Well the US customer service folks are certainly friendly. I received a high heat replacement gasket after I asked for it - not under warranty, so that was nice. I had already bought/installed one from high-que, but nice to have a backup I guess (though I doubt I will ever install it given the spray adhesive, neccesity for cardboard templates for over-spray etc; just looks like a pain).  BGE advised me to sear steaks at 600, pizza at 500 (platesetter feet up, grid on P/S legs and stone on grid), and chicken at 400.

As for the dome falling issue, BGE has not offered any real solution, except to leave the daisy wheel on at all times with the lid open and rotated rearward to add weight to oppose the falling down tendency. This is a duct tape solution that is impractical and, frankly, unacceptable. First, I do not have the cast iron wheel on when I preheat. Second, I do not want to open the daisy wheel fully each time I open the lid, only to readjust it upon closing; even as a newbie I know that one. As best I can determine, the band issue is unrelated to the dome problem - unless - there is not enough separation on the bands to properly tension the springs. But BGE said it was not necessary/advised to remove the springs to reset the bands, so I heeded that advice. The last email I received said, basically, there was nothing they could do.

theres only a few things that can be wrong for the dome to drop. upsidedown hinge (yours is on right), bolts on the lower spring are loose (yours look tight), egg is leaning forward (it doesnt take much lean to do this, put a level on the gasket surfase on the base and check it), faulty springs, either a crack or they are too long, ive had to replace mine after they cracked), the hinge assembly was made a fraction of an inch too short not stretching the spings enough. if its leaning forward shim the forward feet with a dime and see if that helps, i would try that anyways. balancing the dome with the daisy isnt what you want to do, who said that at customer service?

I am with you....either springs or hinge.  I see your point on level ground.  This is all paved patio.  The portion next to the house is (ever so slightly) sloped away from the foundation, but I only store the egg there.  I do clean/fill it there from time to time, and the tenancy of the dome to droop in that location is worse than other areas - any movement of the egg there and the dome will fall closed.  Keep in mind this is an almost imperceptible slope, so slight that I never really noticed it until I had this problem.  On other perfectly level sections of the patio I have the same issue.  I can rotate the egg 90 degrees in a single location and at each position the dome still drops 3 inches after being fully opened.  What has me stumped is that this is a new problem.  I cannot figure out what changed.  BGE customer service said the springs they would send me are the same ones I already have...