The problem with sizing a door to fit a cab or a cab to fit the door is that if door is damaged, you have to make a "custom" door again. Shipping a door to you would be expensive. Why don't you just get one off of local craigslist? A nice guy would even let you try it. If you can get the specs for the door and door opening and check it, maybe you will find out the truck was in an accident and "fixed" wrong. Or the door has been "customized" already. The adjustments provided on doors are so that any door fits any cab. Otherwise how would a collision repair place get a replacement door made in any factory back in the day and fix a truck? How would a modern day replacement door fit? (LMC, Brothers, etc.) One of your items is out of spec/tolerance, find out which one and fix or replace that one TO SPEC. Like I said these trucks had pretty big built in gaps, so you are WAY off. You are correct about the rubber. that is another can of worms with a shaved door or split opening. I have never heard of anyone taking a stock, never damaged truck and start cutting into the door opening to fit a stock door. Bottom line: If you did not notice an interference fit before disassembly, then you warped it. You can confirm this by measuring to specs. If you did, either buy another cab or customize a door. Because you ain't done yet, what if the windshield doesn't fit due to warp (after cab is painted)?, what if the fender won't fit? what if it's racked such that the door has to be a parallelogram? Even if others say they have done it. I would not go down the road of hacking, cutting, shaving, welding, trimming...it could be a dead end. You are a construction manager, you know what happens when you try to start with a wrong part. Ask yourself, "Am I in a hurry here"?, "am I trying to move forward while dragging a chain?"
