Thanks all. The A-pillars were off a little before I added the pads. Now they measure perfect. Distance at the top is exactly the same as the board in the top - and the diagonal and the distance from the center of the cowl to each tip are all exactly the same. The window measures 1 1/4 " different in the diagonals - which I confirmed with the paper cutout. All a bit hard to communicate, and I'm probably not doing a good job. One side of the window seems to follows the contour of the a-pillar very well with a consistent gap - although perhaps a bit larger gap than the layouts above. The other side of the window does not follow the contour at all. I have no explanation.
My frame is a bit different design than the ones shown above - being a 1-piece window. Seems like I'll need to cut out a section of material, bend, then re-connect, then remeasure. It might be a job for a body shop at this point.