Door panel/alignment issue

[J48chevy]

Ok, so I am starting on the cab replacement panels. As you can see, I cut the old rusted outer panel off and then put the replacement one on. My problem is when I go to align the door, the panel has to be moved out the width of a bolt as seen in the 2nd pic. I did put new hinges on as well and there is no more adjustments I can make with them. The door spacing is almost dead on. When I remove the bolt and push the replacement panel in, then the front of the door sticks way out. Anyone have suggestions on this? Everything is straight when the old panel piece was removed.

[J48chevy]

Here is the pic of how far out it is. With the bolt spacing it out it aligns perfect with the door. Has me scratching my head.

[J48chevy]

Could this be due to new door hinges? The part that has me most confused is the top and bottom of the door align with the new panel but the middle part of the door is bowed out unless I gap it with the bolt as shown in the pic. Don't know if I should do something to build up the cab area in place of that bolt to fill the gap. Again nothing is tweaked as it was a simple rust removal and put the new piece on. Don't want to start welding until I can get this gap issue figured out.

There has to be someone on here who has run into this issue. Ideas and thoughts would be appreciated.

[mr48chev]

I think the first thing I would do is to get the door to fit the rest of the cab right getting the style lines lined up and the rest of the gaps right and then fit that panel to the door.


Then either massage the panel's lip a bit or the lip of the door post, both or add some filler material between them.

[J48chevy]

Thanks mr48chevy. After working on it today for a few hours I found out a new panel is not so new and direct fit. Haha. I had to work the lip on the door jam and after a few times removing and reinstalling the door (6 times to be exact) I was able to get things lined up. Never said I was a pro at this and some guys could have done this in no time at all. The joys of learning all of this. At the time it does not seem too much fun but after I finally get it, it is very rewarding. Hope to have more pics coming in the next few weeks. Would love to get the cab ready to mount on and then time to think about paint and prep.

[fine69]

Always remember....these were trucks. They never fit that great when they were NEW. They needed a lot of "massaging" at the factory. Sometimes i find that its better to step away for a few...then come back. Gain a new perspective.