We assume that when you say "a gap at the bottom" and "1/2 inch from the body", the gap is at rocker/step area. You could have used just a step, just a rocker or a rocker-step combo repair patch. If you replaced bottom of door, maybe the "arc" was not maintained. Maybe some other parts of doorway were "repaired". We don't know for sure what, how and by whom. Be open to checking all that. That will be difficult to do. You will have to measure another truck or transfer from driver side. You can make a profile out of cardboard from driver door, cut it out carefully and hold up to profile of pass door and so forth. Just brainstorming here. You are an engineer and so was I. On this issue we must treat each other like normal guys.
You will be the one who figures it out but you have to take it all in first, like an engineer would. Approach it like a pessimist. "Something is wrong here and I have to find it". NOT everything that was done was a professional restoration so that's got to be right. There are no professionals, just guys who don't make mistakes very often. A guy who doesn't trust the trainee with his name. A guy who tries the door before everything is welded up.
The bending suggestion is the last resort and not to be rushed into.
