Geoff,
Oak strips 3 mm x 20mm. Quarter sawn, I am guessing on that though.
Yes, recommend using steel frame as template. Much easier to control timber to frame.
I have removed the frame from the car & find it was grossly over sized .
Able to use glass & alum frame to assist in reducing overall size.
Separate steel frame should eliminate that problem.
The original innermost remnant timber strip is heavily tapered on the inside edge - photo may illustrate situation. Presume it will provide smoother/softer edge for head lining & allow alum frame to slide in .
I have glued 2 strips together - overlapping butt joints to hold the shape and will do the same to the remaining strips when they go in. Very flexible but also very stiff to the lateral curve along the bottom edge of the window.
Might suggest wider strips & shave to follow curve as the alternate option to cutting the strips across to flex will introduce an inherent weakness should there be any water penetration from a break down in the window seal - don't think condensation would help either ...
Yours in passing,
C.K
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