windshield install problem on 31 tudor

[Tom Bellfoy]

Helping a friend to install his restored windshield in his 31 tudor but experiencing a no fit situation.
facts:
1. new repro wood header from Model A wood kit supplier
2. new repro metal cover that fits onto wood header
3. original visor and new roof material installed prior to test of fitting windshield - error # 1
4. windshield does clear the gas cap on opening but not excessively
5. the repro metal cover is fitting tight against the wood header which will not allow the windshield frame/hinge to go back any further
problem:
when viewed from side (looking at end of windshield) either end. with windshield closed by pushing in the bottom, there is a half inch gap at the top
where the rubber gasket should be a tight fit up against the pillar and the bottom fits as it should.
I have read most header/windshield problem posts but cant find any with this specific problem. Has anyone else experienced this problem ? I'm open to any suggestions to resolve the problem for my friends car

 

[Mitch//pa]

Tom could it be that the header needs shaving causing the metal header cover to not sit far enough back? I have done two Tudor wood kits and they pretty much fit like a glove from classic wood... The only thing I had to trim on the header was a little bit on the outside corners for the visor fit

 

[Tom Bellfoy]

Mitch:
glad to hear you responded. That is what I have been thinking but wanted to hear what you more experienced guys such as yourself had to say
Tom

 

[Mitch//pa]

Actually thinking about it that metal panel wraps under and around the header to the inside of the car.. Then the header interior upholestry panel sits into it along the bottom..
So if it was being held outwards you would know it

 

[Mitch//pa]

In this pic you can see what I mean about the interior panel...

An outside view