Cadee,over 150 views on this thread and only one reply...wow,we're not usually this shy!
Like John already mentions the repop parts are not always as accurate so consequently require a bit of tweaking to fit.
I too had a slight issue with mine resulting in me dropping a lense!
I take it,you are using the original shells?
I'm assuming the problem is with the top grill bar stopping the chrome surround and gasket going in and seating correctly?
I put it partly down the the cork gasket thickness,bear in mind the original ones would either have been thinner or just compressed after 60+ years.
You could try leaving the main mounting nuts slightly loose to allow some play,then try and set the glass,gasket and chromes in place,then tighten the nuts.
Two other options, try and get some thinner gasket material and make them the only issue there is the chrome might then foul the side of the grill frame or alternatively play around with the mounting holes in the grill itself,access might be tricky though.
Just throwing a few suggestions to you,good luck.
Last edited by jockbolter50; 08/28/2014 8:04 AM.