I'm starting to wonder if moisture/humidity may have something to do with the variability in air filter sizes, even within a brand, making them at times a bit difficult to tuck into the box. The paper filter is of course a bit fluffy to let air pass and that makes it naturally absorbant. With all those folds molded into a nice flexible rubber base, a little expansion and contraction from being extra dry to being in a humid environment, either pre- or post-manufacture, could make for such differences.
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Dave -still with 940's, prev 740/240/140/120 You'd think I'd have learned by now
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