How in world did that happen? I did not notice or can't remember how the door fit upon disassembly. I have replace rear (lower) cab corner, front inner and inner to outer metal and bottom of outer cowl panel. But, I never disturbed hinge post to rocker panel connection. I tested fitted the door in the opening and the door and opening dimensions are virtually identical.
So, it seems I have some distortion in the cab. Too late to fix now (nor would I know how). So, I have to fit the door to the opening. My plan is to grind both door edges back approximately 1/8" then weld back together. I am unsure what will happen the door skin during this process. Suggestions? Should I spot weld the skin to the inner door before grinding down the edges (which will separate the skin and skin fold).
The door needs extensive rust repair anyway.
Any other suggestions. Incidentally, the drivers side door fit well.
