Did you find that the main front windshield pieces are same-same mirror images and sizes, or did you have to create a separate template for each side to deal with variations?
Very detailed work which should lead to much better fit and less fuss/muss come installation time I think.
I made separate templates for each side. They were off from each other about a 1/2" (iirc) or so in the edge along the A-pillar... but mainly in the top and bottom corner on that edge. It could be that the top is slightly wonky since it was a panel that I added an aftermarket roof to but who knows. I have a '48 3600 that will be the recipient of some pristine aftermarket glass in the near future (along with some other leftovers).
I figured if I was able to get the gaps to pretty much match the nominal rubber thickness that it would make the install go more smoothly. I can't imagine trying to pull the seal in place with a rope with too large or too small a gap. The flat glass should be very close to the nominal gap needed if they are cut to my templates but the corner glass may be a little tighter fit because I could only massage the metal. I have some local areas on the corner glass where I was only able to get a 3/16 gap and I'm hoping the rubber will compress enough to compensate. If not, I can still trim the edge a bit and let the seal ride up the contour a bit but I wanted to limit trimming a painted truck as much as possible.
1949 Chevy Panel Truck A Project Journal I'm old but I make up for it by being immature.
