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I put some quality time in on the left rear corner of the cab yesterday. After test fitting the new patch panel onto the corner a couple dozen times, I came to the conclusion that the "L" shaped corner at the bottom rear (where the rear cab wall notches up) was not going to wind up in the right place if the new corner remained in one piece. It simply isn't the same size as the original corner. So I cut off the corner and clamped it where it needed to go. I figured it would be easiest to get the rest of the corner to fit then fill in the gap (which turned out to be about 1/2" wide). The first photo shows the new corner piece temporary clamped into place with the "L" corner in the right spot. Note the difference in the two surfaces. In order to get the corner to "lie down" and meet up with the rear wall, I needed to get the bottom of the corner to tuck in further. To do that, I had to cut off about half of the "Z" shaped lip where the corner attaches to the door jamb. Then I had to slowly grind away the remaining material until the corner piece was relieved sufficiently.

Before that whole process, however, I took some time to make a couple of patterns from the door. Using overlapping layers of tape, and some strips of manila folder for rigidity, I made patterns of the bottom of the door, and of the rear edge. These patterns allowed me to check the alignment of the new corner piece before I tacked it in. Unfortunately, because the other cab corner is gone at the bottom, too, I don't have any means of gauging how far out the new corner should be from the door jamb. I made an educated guess based on the thickness of the bottom of the door (including the rubber seal). I'm keeping my fingers crossed that the door and the corner faces line up reasonably well.

In the last photo, you can see that after I trimmed the door edge sufficiently, the corner laid down pretty well and was easily tacked to the "L" shaped corner at the rear. The gap between the two pieces is easily filled in with a strip. I will need to make some filler pieces for the door edge as well.