The biggest problem with a incubator is having the right amount of heating power and more is usually better with a proportional thermostat. For me the 11" heat tape has never worked well. My best guess is that if you added another round of flexwatt you would see much better regulation.
Also when you are seeing the variations and reporting the temps is that the temps the thermostat is reading? If not, does the thermostat reading stay fairly consistant? If your reported readings are from the thermometer then keep in mind those thermometers are usually + - 2 full degrees and their resolution can vary too. When ever you are combining a thermostat and thermometers a good idea is to tape their probes together and just let them hang off of a table for 15 minutes before installing them in your enclosure. Then check their readings and write down the difference. This way you aren't chasing your tail once they are installed and wondering if its the enclosure, heat element, ect.
In the pic of the new incubator is the fan/heat setup the same way? If so another issue could be that its rather tall. It looks like you have the fans to blow air across the heat element which allows the air to rise up the back. I wonder if the heated air isn't circulating enough to make it back towards the bottom. You may want to consider adding another small fan at the top pointed down to force airflow back down the front.
One last note: Looks like the flexwatt is mounted with aluminum tape. I know alot of people suggest aluminum tape but they probably wouldn't if they had seen some of the heat tape failures. The elements can burn through the plastic covering. Aluminum will conduct electricity and if that happens you could cause a short (fire hazard) or it could become live (shock hazard). If you use it just make sure it isn't applied over the elements.
Dion Brewington
Owner, Spyder Robotics
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