Those pics sure bring back some recent..and painful memories! Haha! Nothing like scraping the gunk off the roof to build up a good sweat. I sat in there for two nights with a scraper doing that before I could install the new dynamat in it's place. Argh! Keep up the good work!
Best of luck with the hood and bodyshop purgatory. FWIW, I just spend last weekend fitting my steel '400' hood, and the gaps are pretty close also, I had to move both fenders out a hair and remove my hood bumpers also. I 'dimpled' the sides in to clear the bolt heads as well, and was able to put the little bumpers back in. Dang, I thought these old cars had all kinds of room...but apparently not when you're trying to line up the nose and hood on a '69 Bird. My gaps are barely 1/4" all around after much massaging. I had to hammer in all four corners to get that...they pretty much touched. Good thing it wasn't painted yet.
You're in for some REAL fun times when you get to the nose. Mine fits like crap, gotta pull it all apart and start over now that I got the hood on. NOTE TO SELF...don't put the nose on without having the hood and fenders lined up first..DO-OH!!
The new HP Pontiac magazine has a brief article on putting the nose on a '69 bird. It wasn't real informative or detailed, but they did recommend building it up in pieces on the car, checking headlight cover to fender clearance as you go....I'm going to try that method since mine obviously didn't work.
I would recommend, if at all possible, to fit the nose to the car before paint, everything, including the bumper and headlight trim. I wouldn't worry about the headlights or grille inserts. But all my stuff was painted, and it got pretty hacked up in spots where they would interfere. Trust me, you want to know exactly how that goes back together and make and corrections BEFORE you get to that point. Most of mine will get repainted once I get it to fit. The aftermarket valance is a hair too wide, if you have one of those, beware. My sub-structure was bent, but I was able to straighten it out and it works, but I may need to find a new one and start fresh. 1/4" doesn't seem like much, but by the time you get it all together and it's off by that much...it's annoying has heck.