Fashioned a patch to enclose the top of the S10 driver's side door in front of the Malibu window frame. Made a cardboard pattern, cut a piece of 18-gauge, bent ot using a piece of 1/4 flat bar and welded it in place.
Once the top of the door was tacked in place, I started on the roof-to-door frame opening. I started with a piece of the S10 A-pillar that was already shaped. The Malibu roof edge had been roughly braced and suspended over the top of the new window frame, so a proper attachment to the S10 door frame is necessary to form a viable A-pillar. The first photo shows the patch piece as it was removed. The second shows the gap to be bridged. The third shows the patch piece tacked in place and the fourth shows another patch piece formed to hold the door weatherstripping.
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.