[SydneyChris]

thanks gents.. will check in with the engineer and see where to go.. can get 95% of the travel required.. so its not a bad solution.. just not seamless in the application.

To get the door frame and A pillar parallel, I was thinking of slitting down the front of the A pillar fiberglass... taking a very elongated triangle section out of the face to move the return edge inboard and also slit it half way at the base, then patch it up.

Will enable the finish to look consistent and I can grab another 5 - 10 mm and get the glass to door frame clearance required.. will need to fit and fasten the body before I go much further though.