Billhilly, Its great the cab repair dvd's are help to you. There was over 200 hours of repairs to the cab in the videos and over 100 of it was fairly typical rust. I couldn't get every issue in the videos or it would take two weeks to watch
Some people have asked about the audio. The videos were made by a fabricator on a small budget and not a professional film maker with professional script writers. When the audio drops out, its where I said something wrong or something made no sense. Talk to yourself all day long while you work and tape it, you'll see what I mean...LOL...
Anyway, back to your truck. One thing I thought about is the above suggestion was considering you had the cab corner and outer rocker done. If not, try aligning the door to the upper b pillar area from the character line up by tilting the door in at the top, then move the bottom of the cab corner and outer rocker out to meet the lower section of the door. Also keep an eye on the door seal lip as you may need to adjust it when you're happy with the way everything else fits.
As I always tell everyone who purchases the cab repair dvd's, feel free to contact me if there is anything I can help with....eb