Fitting the windshield to the cowl. Evidently IMs, CMCs and Fiberfabs all have a gap between the windshield and the cowl in the middle area. Some past remedies include Bondo (and painting), grinding the glass to fit, and tipping the windshield forward with shims under the rear post area.
I decided to reshape the rubber seal so that it matched the curves better. Essentially, I used a very sharp razor to shave material from the areas where the windshield rested on the cowl until it was a better fit.
I took the posts off so they wouldn't get in the way and marked the cowl so I could repeatedly put the windshield back where it would be mounted. I would look under the seal and see where it was in contact with the cowl and mark the glass over the area I wanted to shave (using a china pencil). Then I would remove the windshield and use the razor to remove rubber from the area that had been in contact. Rinse and repeat.
After about an hour I had a much better fit that would work well with the trim piece and should be easy to seal using Dr. Clock's recommended DAP black acrylic/silicone caulk.
I suspect there's a lot of individual variation between cars and brands of under windshield rubber. It like it because it lets the glass float with less tension than I used when I did my first fitting. Some pics:
Leave enough rubber so the windshield can float in the frame and on the cowl.
An hour's worth of rubber shavings
Marks on glass show where rubber makes contact. Check both front and rear of seal while tipping the windshield back (like the tension rod would do).
I found this at Ace. Thanks for the tip, Alan.

