Flush mounting glass

[BA.]

on my car they did it a lot like you said. there was a lot of trial fitting on each glass and the shop worked with their local Glass Shop that they always use.

on the sides of the glass, you can just weld in a rod or some flat steel bar to help close the gap, then dress with duraglass.
on the top and bottem, it depends on how you position the glass (up or down, or centered).
My front glass was mounted lower and they then had to lower the roof-line. If I would have been paying more attention to things, I would have used the original roof-line and added metal to the cowl panel.



I don't remember the gaps but the Glass Shop gave recommendations for expansion clearances.
I'll try to get a picture for you of the gap. There's a couple of crappy garage shots in the link in my sig.

EDIT: The Glass Shop also had the body shop put in a slightly wider ledge for the glass to sit on, so that the butyl would have full support.