Agreed Kevin... it was a rookie mistake that I won't make twice, since I am not a rookie anymore (the mistake was not knowing to observe door fitment before disassembly). I also reserve the right to trim the door to get the right gap, once I replace the passenger side cowl, rather than cutting the cowl. My hope there is that I can position the new cowl piece to achieve the desired gap now that I have the door hung as a reference.. . Same thing with that recommended cut on the rear of the cab... maybe able to get the right gap by trimming the lower part of the edge of the back of the door. I also agree about doing it right on making the 3/8-24 bolt work rather than using the 5/16 bolt.
Look at Raybuck part # 0846-132... passenger side cowl, no louvers.
Thanks, as always, for your proactive support.