OK, just an update for the next doofus working this problem.
I took off the front fender and started over with the door. With the fender off I could see the upper hinge center bolt, the one way in the back, is supposed to be captive. Someone bent the tabs back away from the nut so it spun freely.
In order to get the fender off I had to free it from that front fascia piece that goes behind the grill. I loosened that fascia piece and will shim it forward ~1/8" so I can move the fender forward that same distance. Hopefully that will create the clearance I need between the fender's rear edge and the door's front edge.
BTW, this aftermarket door does NOT have the correct curve to the area below the window. The top of the door is snug to the cab but the bottom sits out too far. I'll go back to it tomorrow a.m. when temps are back below 100, but I don't think there's any more adjustment in the lower hinge.
