I removed the windscreen locking strip to put sealant in (as the panel beater put it in w/o any). I stuffed mastic sealant along the outer lip (to body) as well as along the inner lip (to glass).

Puting the locking strip back in was easy using a wire tool, but I ended up with about 5cm worth of extra locking strip lenght (thats not a new locking strip but the actual one that was already installed in this windscreen and was spot on before removal). I doubt the extra volume of the sealant could accout for 5 cm, so what have I done wrong?

Oh and the windscreen rubber is a bit loose at the top corner. When installed by the p.beater it was buckled on the inside. I managed to straighten most of it out but the rubber can still be pushed slightly outwards, and pressing on the w'screen in that corner can make it move inwards a bit. Its my understanding that once locked properly both the rubber and the screen should be unmovable so once again - what have I done wrong?

Not sure about the top corner, but it's not unusual for the locking strip to stretch while you're putting it in. I've know people to leave a couple of inches excess hang out for a week or two to let it shrink back before cutting it to size so as to prevent a gap forming.

Probably nothing, but sounds like the windscreen seal is distorted - they should curve nicely into the corners. You may have to try another seal which obviously means removal again

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1967 Cooper S - new front bearings to do.
1965 Cooper S shell - Slow progress. No time or money!
1966 Deluxe- next rustoration!
Mk 2 & XJ6 Jags. Less said the better.