The Double Shell Program at Los Alamos National Laboratory is studying an alternative platform for achieving robust alpha-particle heating at the National Ignition Facility. Double shells benefit from having a low convergence ratio and lower predicted temperature for achieving volume ignition. The joint required to assemble a double shell has an imperfection in the outer shell that seeds instabilities that can greatly impact the inner capsule’s implosion at bang time. Different variations of the shape and placement of the joint were implemented with improvements in the quality of the machining leading to measurable improvements in yield. High-Z coatings on the outer joint mitigated the impact of the 1- to 2-μm gap sometimes found in double shell assemblies.