You sir, are a genius.
I bent it back and it works PERFECTLY.
I honestly think it's small defect with the strength of the tabs.
Heres what happens (and it's prob. already been said):
When you first pop off the cover you bend the tabs slightly. So you try to put it back on their obviously loose. If you bend back down as hard as you can (you won't be able to snap aluminum or break the heat welds, if so Apple owes you money) the tabs should fit snuggly back into the small slitted space. Your cover should fit like a glove.
Thank you. I'm glad I could help.
I think you may be onto something here. The first time that people are removing the cover, they aren't sure where the tabs are, so they just pull back, bending the tabs. Makes sense.
Hopefully Apple will release replacement covers that are a little more resilient.
As far as your question, Clayne, I think a light flex in the affected area may do the trick, but just be careful to not bend the entire thing.
It may also be the way in which the two main clamps are sitting inside the MB. I that case, a flex may help a little, but it wouldn't be addressing the problem.