I figured I should complete the junction between the Malibu roof and the S10door opening before enclosing the area with the outer panel and windshield frame. First, I thought I should finish the top of the S10 door where the Malibu window frame attaches to the door. The first photo shows the gap at the top of the S10 door. I made a pattern out of cardboard, cut a piece of 18 gauge cold-rolled steel to match, and bent it using a piece of 1/4" x 1" flat bar. I left enough on the outside of the door to cover the relief on the S10 door intended for the original window molding. I also matched the piece to the inside edge of the door panel.
After fitting the windshield into the mounted frame, I found that the edge of the glass would be an inch from the edge of the existing Malibu door frame. I don't think this would look right without the rubber gasket as I plan to mount this glass only with urethane. I also need to fashion a piece to fill the space at the top of the A pillar between the top of the original Malibu rear window and the new windshield frame. A while back, I purchased a small English wheel, so I decided to make a first attempt at using it.
Now the windshield frame is finally tacked in place. It's close to the marks I had before working on the defrost vents, so I am happy I did not distort the frame. I still looks square (the photo was taken slightly off the vehicle center line), so I am ready to start on attaching the roof from the 58 Chevy.
It's been a while since I've posted an update. I've been working on defrost vents to go in before I fix the windshield frame in place. Here's some photos of the vents attached to the windshield frame. I bent some 1 1/4 inch tubing to a series of 90 degree angles and cut the bent pieces to fit. The vents housings are fabricated from the internal braces I removed from the 2001 Malibu door frames. I cut them to the desired lengths and welded some 18 gauge pieces to the ends of each vent housing.