[DogMeister]

So after a lot of investigation, it seems that no one makes a reproduction header panel that fits the repop trim, and no one makes repop trim that fits the repop header panel. I was able to get the mounting studs and holes to line up, no small feat, but the curvature of the header panel and eyebrow trim to not allow for final assembly.

It looks to me that the header panel is at fault here, as the inside curve toward the 'nose' is too great a radius on both sides. I had repop trim on an original header panel and it fit with [almost] no issues. Unfortunately I do not have that car any longer. So far my search for a used original header panel has not panned out, but I haven't started checking the swap meets yet. Regardless of the source, all the panels and trim online look the same.

Other than having my body guy ruin, reconfigure, and repaint the freshly painted existing header panel, anyone have any suggestions?

[ZeGermanHam]

Where have you searched for an original header panel? I have found that Facebook is by far a much more fruitful place to find & buy used original parts. In particular, the Pontiac Parts Swap Meet group. Every time I create an ISO post, I always get multiple replies from people who have the parts I'm looking for, including an original header panel I bought for my '66. If you haven't tried Facebook already, give it a shot. It has way more activity than the classified section here, or eBay, etc.

[DogMeister]

Thanks man. I'll give that a shot.

[ZeGermanHam]

No problem. I recommend actually making an ISO (in search of) post rather than just searching for what people have already listed for sale. In my experience, people tend to come out of the woodwork when you ask for a specific part. Good luck!