yeah can't be the paint - there is too much space for it to be because of it...

The roof should be well aligned as I have already fixed the back of it and it all went smoothly, so I was thinking either:

1-it is the new seal which is very thick
2-I should loose all the bolts between roof and body and fit all of them more gradually
3-something happened in the 2 weeks that the roof was detached from the body - can it have bent as it was being supported by two wheels at the front/rear ends of the roof which is 5 meters long (Wheely it's 3 axle) so the middle section which wasn't supported messed up the shape of it? I'd think unlikely but could be an alternative
4- ???

I would have thought that when the roof to the windscreen frame was tighten up also the seal between windscreen frame to bulkhead would have tighten up from being so loose now...

grateful for your thoughts

I presume you got this sorted and everything is now OK, however I found this post when looking for how to refit the seal to the roof of my Defender and thought this may be useful for anyone else that finds this thread - Looking at a Video from Britannica there are two different seals for the roof. Here is a link to the video for anyone who is doing this in the future.

Fitting the roof seal to a Defender - some notes - YouTube

PS - Sorry for resurrecting an ancient thread!
 

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