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I have tried a few window catches on my 67 Cooper and none seem to fit into the respective holes in the channel and am wondering if the channels have been fitted correctly. Can anyone advise me on this please?

I assume the holes arer either too close or too far from the glass for the little peg to locate correctly, when I fit the channels I engage the catch in the hole to make sure they line up correctly before drilling.

I suspect you may have to remove them & move the channels to suit.

That sounds like a plan. The pegs miss by about half a hole so I will dismantle the whole thing then line them up. Is just screwing the 4 self tappers sufficient or should there also be some sort of weather-proofing too?

I use sikaflex & screws on mine.