After looking over the bone pile of 100+ door shells and the 50+ trucks in the lot, I have come to the conclusion, that the problem is not consistent, nor present, across the board. I have some trucks with the doors still swinging, that look great and some that look a bit out of whack. Also, the door shells, appear to be the same scenario...neither consistent, nor present, amoung all the doors.

The various manuals, specific to the '60-'66 Chevy trucks, have extensive details of every section view, where panels come together, which specify the +/- tolerances of each gap. Although automation, in the manufacturing & assembly phases of the automotive industry, has taken the place of the factory assembly-line workers, I believe tolerances, during the assembly process, was a function of the QC standards of the guys on the line.

Last edited by 4-5-6 Chevy Trucks; 01/06/2013 12:05 PM.