HELP !!! Sheet metal alignment
 

I'm new to the forum and need some good input on my project. I've replaced inner and outer rockers, partial floor pans and started doing assembly before I take it back apart for paint paint. My problem is the passenger side door. When I fit the the door the front edge of the door is 1/4" behind the rocker. The driver side is even with the front of the rocker. I've measured from the A-pillar back to the front of the rocker and it is the same on both sides. I can't move the door anymore foreward. The cab shows no evidence of a hard collision. Any ideas ? Is the front of the door supposed to be even with the rocker ? I should have taken pictures before teardown.

Re: HELP !!! Sheet metal alignment
 

How does it fit overall everywhere else. Is the gap consistent all around? Have you test fit the fender and checked that gap? It is not uncommon to have to build an edge with weld to get the gaps like you want them. Tolerance on fit was apparently very high, no ball bearing rolling around the door gaps from the factory for sure. Pics would be nice.
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Re: HELP !!! Sheet metal alignment
 

The other gaps are fair. It's surely won't be a show truck but I would like to make it fit as well as possible. I've got to much time invested to not do it right. I'd like to know how some other nice fits look. How much gap should be between the fender and rocker ? Should the fender touch the rocker ?

Re: HELP !!! Sheet metal alignment
 

also I don't think gm's standards for trucks were as high as we put our standards today...

Re: HELP !!! Sheet metal alignment
 

Look at the thread of pictures this forum has. I am going though a similar thing as well. I went through alot of pictures this last year to get info on alignment of doors,rockers, and fenders. From my picture collection, they are supposed to be in-line vertically at the front. Unless you spend alot of time, there is some mismatch. I would post a pic, but im not sure how yet. Look through the picture thead.

Tom

Re: HELP !!! Sheet metal alignment
 

Attachment 651769


....did it work? yes it did, i posted my first pic...lol

Re: HELP !!! Sheet metal alignment
 

When ever I restored my last camaro ot even this truck we used painters mixing sticks to set the gap, they are the right thickness as far as the door gap, fender should line up with the rocker end point... with about a 3/16 gap to door.

Re: HELP !!! Sheet metal alignment
 

Good luck Mr. Phelps.....

http://lh6.ggpht.com/_jlNKkl-rSbc/TG...2/image0-6.jpg

Re: HELP !!! Sheet metal alignment
 

Aero, you are a wealth of awesome information. Thank you for all your input. I always learn something!
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Re: HELP !!! Sheet metal alignment
 

Thanks for the pic's guys. I'm going to finish the body work on my hood and front fenders to get my mind off of it for a little while and come back to it later. When I get frustrated I have to do other things for a while to let my nerves settle down.

Re: HELP !!! Sheet metal alignment
 

Be sure your hinges aren't sloppy as well. If they are, it will really make alignment difficult.
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Re: HELP !!! Sheet metal alignment
 

Thanks, we rebuilt the hinges before we started trial fitting. I guess if all else fails I can shorten the rocker to match the door if that makes the fender and everything else line up properly. I will check everything possible and get several sets of eyes on it before I rush into anything though.

Re: HELP !!! Sheet metal alignment
 

I noticed in another thread that a member was having trouble lining up their doors.
A little tip that might help those using the same doors on the same cab is to trace around the mounting hinges. Perhaps make permanent marks in the metal so they still can be seen after paint. I re-hung my doors today and just lined them up with the outline of the hinges and all is as before.
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Re: HELP !!! Sheet metal alignment
 

or drill a 1/8" hole through the hinge and it's mounting surface before you disaasemble. you then just need 1/8 line up pins to put it back in place
ron

Re: HELP !!! Sheet metal alignment
 

Drilling an 1/8" hole before dissasembly helps a ton to get the sheetmetal back in place when it's time to put everything back together. If the gaps are still uneven, you can weld 1/8" welding rods on the edges of the panels to close up the bigger areas. I made a "how-to" thread over in the body/paint section that shows the process.

http://67-72chevytrucks.com/vboard/s...d.php?t=497761


Here's what can be accomplished with enough time and effort.

https://fbcdn-sphotos-a.akamaihd.net..._4265079_n.jpg

https://fbcdn-sphotos-a.akamaihd.net..._8252680_n.jpg

https://fbcdn-sphotos-a.akamaihd.net..._3150269_n.jpg

https://fbcdn-sphotos-a.akamaihd.net..._1673251_n.jpg

https://fbcdn-sphotos-a.akamaihd.net..._1151974_n.jpg

Re: HELP !!! Sheet metal alignment
 

^now thats called giving a crap! Huge effort man, impressive.

I've got my doors off now, and have been avoiding thinking about the eventual alignment.

Re: HELP !!! Sheet metal alignment
 

Awesome Idea!
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Re: HELP !!! Sheet metal alignment
 

Put in weatherstripping first, as it will tend to push the door out in some ares.