Denny,as I'm sure you're aware laminated safety glass is available in a variety of thicknesses.
Over here the autoglass industry tend to stick to two main thicknesses.
When replacing flat glass in older vehicles we tend to use 5.4mm thick for side/bodyglass although I do prefer to use tempered glass for drop glasses,and 6.4mm laminate for windshields(a legal requirement over here.)
As you say setting tape is available in a large range of widths and thickness to compensate for any discrepancies.
I tend to treat each job individually as different manufacturers glass channels varied considerably over the years which then has a bearing on the materials used.
I used urethane to secure the lower sashes on my own
door glasses and a 'U' section rubber seal for the frames,and while this is not obviously factory accurate, I'm more than happy with the results.
