Hi Bob,
If you bought the EarthBox Root & Veg close to its launch, you likely got ones with the 1st generation screen. We recognized this defect and have since corrected it by introducing a 2nd generation screen. The wicking chamber areas have added support to increase stability and longevity, and the bottom of the screen has also been reinforced to prevent warping.
Glad to hear you were able to create a DIY fix for your existing ones. We did offer free screen replacements for those with the 1st gen screens. If you're interested in replacing those, just email customerservice@earthbox.com and we'll send you the 2nd gen screen, free of charge.
Andrew - E-Commerce Manager
Novelty Manufacturing Co