I'm trying to make some simple door panels out of 3/16" ABS plastic for my '52. The panels will be covered with fabric when done.

Here is my problem. When I secure the panel to the door, it rubs against the door lever machanism causing it to bind up. I can get the handle to work if I space the panel out, but then the stud for the handle is too short. The regulators are new reproductions. I really don't want to space the panels out and I don't want to add extensions onto the studs.

Before I cut, grind, weld and redesign the regulators, I thought I'd ask if anybody else has had this type of problem and how did you resolve it. Are the reproduction regulators my problem?

Thanks.