Bartamos,
In hindsight a person should have been more aware of the fit before the repairs. However, the door frame wasn't modified at all. I only did the cab corner. I suspect this truck had a small crunch at some time as the amount of bondo I've removed is significant. The "cut" you see is just the belt line. The paint has bubbled away on it and it was just that way.
I have tried the door fit without the hinges and this was as close as I got. I will try again now that I have Wayne's measurements.
Maybe it's the door. I might have to pull a parts door to find out.
Which other adjusting bolts are in the front fender? I know of the hinge adjust and the ones on the door itself. There are more?
Thanks!
We will get this problem fixed!!