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I used 1/2" foam, so there is a bit of squish for a good seal.
If you look at the parking lot photo, note that the top edge of the cover is not uniform. I noted it was high on the starboard side after mounting it (combination of cutting boo-boo and mounting misalignment), but decided not to fix it due to a time limitation. If I make a version 2 I will raise the port side by an equal amount. That will help airflow bypass the gap. I will take a side view of the grille area sometime soon, so you can see the relationship in a more 3-D-ish shot.
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