So, I did a little more comparison from one side to the other. The drivers (left) door fit perfectly (about 1/8" gap all around). I measured the opening at both hinge locations (from hinge jamb to strike jamb). Then I measure the right side (problematic side). the opening on the right side is consistently 1/8" narrower (smaller) than the left (good) side. Now, if both doors were the same (Unfortunately, the left side door is away getting oil canning removed from the skin...something I learned I cannot successfully accomplish without making a mess of things) then the right (bad) door should fit in the opening with say 1/16" gap all around. But, the right door wont even fit in the opening. It is 1/16" or so wider than the actual opening.
If my metal work was bad, I would expect a pinch at the bottom of the opening or something similar, but the problem is very consistent over the entire opening. Nothing on the cab seems out of whack and I am confident I did not introduce errors. The door is just wrong. Remember, I did not replace the rocker panel and never completely cut either jamb loose from the rocker panel.
So, two choices for me: Cut .156" (5/32", I think I did the math right...half of 5/16") from both sides of the door, or get a "new" door.
Last edited by DavidF; 08/26/2013 9:45 AM.
