I think Mark hit the nail on the head with his suggestion. Review the door alignment instructions in the service manual. It calls for a 1/8" to 3/16" gap along the front of the door and flush to 1/16" proud of the cowl panel. If it's too tight, it'll rub on the edge of the cowl when opened (or won't open at all.)

Kevin
1951 Chevy 3100 work truck
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1929 Ford pickup restored from the ground up. | 1929 Ford Special Coupe (First car)
Busting rust since the mid-60's
If you're smart enough to take it apart, you darn well better be smart enough to put it back together.