Jerry:
I also have 57 TF. I rebuilt the passenger door, hinges and all the components on the bottom of the door frame (hinge pocket, tread, floor pan, cab supports, inner pockets and outer sheetmetal. When it came time to locate the door, I encountered all the problems everyone talks about. This is a frustrating job. I took the door off & on about four times. However, I did find that the trick of duct taping bits of flat wood paint stirrers around the periphery of the door frame helped to initially locate the door fairly close (at least a good start point). Also, on my truck I found that the structure where the door hinges bolted to (hinge pockets & frame) were rotten, bent or malformed. It may be worth taking a close look at that. The fact that when you tightened the hinges and some un-intended movement occurred, may be a sign of some deterioration in the door frame. Good luck, this a frustrating job even when everything is sound. You might try searching some posts on this site. I remember I got a lot of good advice from them regarding hanging the doors.
