I keep getting excited about another local member, then disappointed when I see your location...
Jason, He said he's
FROM Idaho.
Scott, your mistake was not waiting to weld anything till you had the door opening matched up with the door. And what you've found is that patch panels NEVER fit correctly and need to be massaged to fit. The fender bolt hole isn't as important as the door fit, as they're not visible after final assembly. What I would do is cut the patch loose, maybe at the front edge so you can make the door gap correct. Put the door on at least temporarily to get your patch panel in the correct location, and use sheet metal screws to hold the panel in position, then remove the door for welding. Also, be sure to tack weld it in place before welding in completely, because if you weld from one end, the opposite end will squirm around. The excess material that laps over the door post can just be hammered over the door post (that's what the factory did.) You may have to buy a new patch panel if you don't have enough material to adjust it and get tight gaps at your weld joint.
You can trim the door edges, but that's not the best approach. This is the voice of experience talking as I messed up my door fit and had to do that.
I'd recommend you head up to the top of the forum and review MPandC's sticky thread on MIG welding tips.
