Hi Zookeeper (and anyone else interested...)
Your interest and the fact that I was candling this weekend anyway inspired me to go ahead and do that thermostat knob modification we were talking about.
1. I started with about a 2 1/2" piece of good, stiff, reasonably straight bailing wire. A large paper clip straightened out could work also.
2. Using some needle nose pliers I put a 90 degree bend in one end of the wire making about a 1/8" long leg... Like an out of proportion letter "L"
3. I drilled a 1/16" hole in the top of the knob. I had planned to go about 1/8" deep into the knob but found out the knob was hollow so it went through the knob top. (You noted your knob already had a hole for a screw so you can just skip this step.
4. I used a small file to cut a little notch into the top of the knob about 1/16" deep running from that hole outward across the knob. This made a little recess for the wire to lay in. This step is not essential but it will make the glue joint stronger.
5. I put the small leg of the bent wire into the hole, checked the length of the wire and trimmed as needed to make sure it could swing all the way around, clearing the bator power cord but still extending over the styrofoam in any direction needed.
6. I placed a drop each of thick CA glue (super glue) on the wire end, the hole and the notch. I let that dry and then applied several more drops on the assembly to build it up abit.
The end result...
I have a less sensitive adjustment handle and a way to pin it in place once I get it set. Now if I see a temperature shift I will know it is related to the limited precision of the thermostat and not related to an adjustment knob moving.
Regards...