Ok, I'm returning to this thread after some more observations. I used 3 #4 x 1" screws straight through the wedge, wax, and top bar, and it worked like a champ - no more tearing of the wax out of the top bar.
Now the problem is that the wax is tearing and the wires are pulling out of the bottom bar(split bar design). Seems to start ripping in the center along the bottom bar. I put a couple of #4 x 3/4" screws through the split bar and it does close the gap and hold the foundation nice and tight, but it bows the split bars and I fear it may cause the bees to draw the comb to a lesser width towards the bottom of the frame.
So my questions are...
Will the closing of the bottom split bars cause the bees to build out less?
What are some better ideas than screws through the bottom split bars?
Better Bee used to make a nicer wooden frame. The current wedge style top bar frames have a thinner top bar, no deep groove in the top bar for the foundation to fit in, and a thinner wedge that I can't take a #4 screw perpendicular through it. Does any mail order outfit make a nice frame like the old BB?