Like other builders of a 40-47 pickup, I ran into the "outside door installation puzzle" recently when attempting to install a reproduction handle. A quick search of this forum, and especially the discovery of some posts by Elder Rodder, soon had me understanding the issue. Like everything else, they needed some modification. The shaft needed to be shortened and a section of about 3/8" of the shaft need the edges relieved or "notched" to allow the handle to pass through the door latch receivers and be rotated into the correct position on the door (later I found an original handle that fully showed what changes were needed). I can't add anything to that good, previous discussion but as no pictures were available, I thought I'd add a couple here that might help someone that doesn't have an original handle to use as a template. Here they are:

 

Excellent pics. BTW... You are not too far from me. (Neosho, MO)

 

Thanks for posting the pictures. This will be a great reference!

 

Sorry for the hijack, but our new '41 lacks a key and when I peer through the hole in the jamb I do not see a set screw to loosen for removal.
Am I out of luck or?

 

I ended up replacing mine with a set from a '34 (I think). They were much nicer and lockable too.