I think Carl hit the nail on the head. These two pics from your earlier post show the damage to the cowl, which pulled the outside edge of the hinge pillar forward. If it wasn't corrected before welding in the new part it would cause exactly what you're seeing. It could be fixed by drilling out the plug welds from cowl panel to hinge pillar and pulling the hinge pillar to the rear. It probably wouldn't take much movement to fix. FAM Section 1 Sheet 63.00 shows the section E-E thru the upper hinge with dimensions from the door edge opening to the face of the pillar.
But your adjustment of the spring slot in the hinge may fix it with less hassle. Hope that works out for you.
Kevin 1951 Chevy 3100 work truck Follow this saga in Project Journal Photos 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.
