After an hour of measuring, filing and fettling I managed to get some offcuts in place ready for filling:
I also decided to grind down the screwheads each side; even though I countersunk each it would look naff not being painted and I wouldn't get a flat finish without at least taking a bit off. Why not go the whole hog and grind them completely? Yes, I will need to take the frame off should the glass crack - but I will likely have to do that anyway so preferred to go with looks rather than "what ifs":
Some decent body filler, sanding, patience and a few more coats of paint later I managed to get it fitted. Again, not many pictures but here is the finished result:
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