Thanks for your input Skiboy. Good to get information from someone who has already been through the process.
As for how I profile the corners, i'll wait until I have the rear quarter window frames and the rear window panel in place before deciding how I do the corner panels. At this stage I am leaning towards something with a radiused edge (more work...).
I have another update.
I bought some foam cored card and cut out the rear window panel profile I came up with and placed it on the car:
https://www.aulro.com/afvb/images/im...012/07/167.jpg
https://www.aulro.com/afvb/images/im...012/07/168.jpg
https://www.aulro.com/afvb/images/im...012/07/169.jpg
The profile above is basically 10mm inset from my original drawing because some of the glass will be hidden by the rubber seal (I assumed it is around 10mm). Also the bottom corners have a 50mm radius instead of 30mm, I was concerned that it might be a bit much to ask a rubber seal to go round a curve on a 30mm radius. Actually I am even wondering if 50mm is too tight?
Anyway, I was happy with the profile when I was in the workshop looking at the car, but now looking at the photos, I'm wondering if the window is too... large, and rectangular? it's hard to judge because the edge of the sheet isn't actually the true edge of the bodywork. Any thoughts or opinions, let me know.
I also finished up preparing the lower part of the rear wall (ex Nissa Navara). With all the spot welded stiffening removed it is one flimsy panel:
https://www.aulro.com/afvb/images/im...012/07/170.jpg
I quickly fit the navara panel on the car and it looks like it will fit in beautifully :D
This will be the last update for a few weeks. On Monday I am off overseas again, Thailand then Oman.

