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so recently, I have been replacing floor patch areas and just completed my driver door post along with a new front cab mount. I hung the door trying to match up the cowl i'll be replacing and WOW!...I cannot for the life of me get the door flush around the top and along the front window pillar...I could solve thing problem if I honed out the door studs and use nuts but once I place my cowl i'll never be able to romove the door again...I NEED HELP!
I had similar problems. If I understand correctly, it sounds like you have mislocated one or both of the hinge pockets.
Try to align the door top and window pillar, ignoring the fit to the cowl and tell us what gap you have at the front cowl face. The cowl corner can be fudged to make up a lot of mismatch there.
I can get about a 1/4 inch gap all around, its the top that's "sucked in,"...and the bottom rear that's pushed out...possibly when I replaced the lower door post I missed aligned. I tried setting the post while the door was hung...but maybe it got sucked in somehow...I did try to tweek the door by twisting the top front but it did little to adjust...
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