Bob,
Thanks for the response. It gives me comfort to know I am on the right track. All my repair panels came in yesterday and you are exactly right...they don't fit all that well. I think tacking and checking...and then double checking with the door remounted is the order of the day. Once everything is tacked and the door fits all around the rubber flange evenly, with a uniform gap on the outside, it would be safe to do the final welding. Thanks again, Jim.