I have the same issue in my 2016 vintage KK23 and Double Bottom Drip (DBD) Pan. I thought until today (seeing Syzygies' fit) the interference was an issue with all the DBD pans. I also had the same issue Tony relates about the pizza stone and the upper grate, which I resolved as he mentions.
This thread prompted me to look into it further. I don't use the DBD pan too often, mostly because it doesn't fit where I want it on the middle grate. After some checking this afternoon, I believe the actual issue is the handle location on the DBD Pan, not the bend or lack thereof of the middle grate handles.
The actual balance point of the DBD pan is located in the forward 1/3 of the handles (as they are welded on the pan) noted with the blue tape on the photos below, instead of at the center of the handles. The handles could (should?) be welded to the DBD pan approximately about 1 1/2 - 2 inches (3.8 - 5 cm) forward of their current location (at least on mine), at which point they would clear the middle grate handles and actually provide better balance for the DBD pan at the center of its handles. Which would be helpful if the DBD pan was full of water, drippings or stainless steel chain...
This would eliminate the need to bend the middle grate handles (and risk a broken thumb, as I can attest from experience as these do not bend easily, at least as it applies to the charcoal basket. But that is another story). Such a method would require a significant bend on mine to clear the DBD pan handles and also reduce the clearance between these handles and the KK body (which may be seen in Syzygies' photo). I assume the curve in my grate handles was done to provide better hand clearance when placing the grates into the KK (Thanks!).
Changing the location of the handles on future DBD pans to their natural balance point would seem to be a more elegant and simpler solution.
Some photos for context.
DBD pan on middle grate in an appropriate location for cooking on the main grate, which would be located above in the actual KK, showing handle interference:
Blue tape indicates the natural balance point of the DBD pan in the front 1/3 instead of the middle of its handles.
Moving the pan forward on the middle grate still doesn't clear the grate handles and runs the DBD pan into the "T" handle of the hinged part of the middle grate:
Moving the DBD pan forward to completely clear the handle interference between the DBD pan and middle grate handles results in the DBD pan too far forward to fit into the KK.
Obviously, I have a lot of time on my hands given the U.S. and Kansas stay-at-home orders. My apologies for the length. As for my DBD pan, I will just continue to locate it on the charcoal basket handles rather than try to bend the middle grate handles. One broken thumb is enough.
Just a friendly suggestion for future KK improvements...
Jon
