Brian,
These doors can be a REAL bugger to align without repairs to the cab. My guess is that you may have not gotten the drivers side door hinges back as they were originally from where you deformed them. Did you support the cab with tack welded cross bars before doing the repairs? The cab may have moved or flexed. You will need to measure your door frame and make a comparison to the passenger side as well as measuring the driver side door and frame. Pictures would REALLY help! On the bottom left hand corner of the Stovebolt page is a link as to how to add pictures to this forum.
Tim
