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The variations in glass are strictly manufacturing quality issues. the bodies will vary on late model cars and very early push buttons but the glass should always to be the same size. You can make even the poorest fit class work but the time involved and modifications required to seal it are difficult.

I built a new windscreen/windshield master for the new body design several years ago that kept the upper roof and A-pillars the same but extended the lower bottom fitment out all most a foot which raked the glass significantly.

Here is a side profile shot of the shape installed into a Pantera. You can clearly see the increase in rake but still maintaining the A-pillar rake---not relevant to the thread---just another trip down memory lane where I stubbed my toe. (Red Face)

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Kirk, if you're going to all the trouble of making a new cowl panel, why not drop the lower area where the glass sets, and rig the Pantera to have real disappering wipers? Sure, it would take new glass, but that's what this thread was all about, and maybe a sharpie like you could find a deep windshield from a Z-28 or something that would fit the new configuration?
BTW, I tried to e-mail you last week; please send me a post at
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