It seems to be a csse of "if you can't raise the bridge,,,lower the river."
Weber can't seem to get a handle on poor fitting doors, so they changed the opening.
Reall? The opening is an oval now? yes.. originally it was a more tradtional in shape. the radii in the corners prevent the metal from tearing during fabrication.
proper fitting doors are easy.. it was done once before, right? do a side by side comparison of the 2 doors and you'll see the difference.
you could do optical comparisons of the two and pull dimensions; take photos of them and bring them into a CAD program with proper scaling; have a master model maker to make a tool.. that's just 3 off the top of my head. but if you don't do anything to fix it... what a shame.
Not an oval, but rounded corners at the top. The pre-production unit Weber sent me as well as one I bought in 2010 both have square corners at the top of the opening.