My door alignment nighmare is here !
 

And yet another first timer horror story. Doing outer floor, rocker and both piers. Have rocker on PS 90% welded on and before doing rear pier decided to "test fit" door and I rebuilt hinges. The truck previously had both corners done. Doors are original from what I can tell and the famous foam treatment had been used in/on corners and rockers and door etc. The corners were filled with foam as well as along the back of the cab, as they were not tack welded back onto the back of the floor when they were replaced

I have scraped out all of the foam from the cab/floor seam, made sure that the new rocker did not protrude out past the back of the original floor and even when i press in from the outside back of cab to get it snug to the floor, the gap is huge at the latch side. I am talking almost 1/2". I have put new cab bushings in and have them just snug. Front end is completely off.
Door sags about 1/2" down at back corner as it sits now.

Camera is charging now will post pictures in a few hours. Just needed to vent now. LOL (Have read numerous threads but have not seen this problem to this extent.) I am thinking that all the foam tweaked the cab corners but even when they are pushed into the floor where I could tack weld them back on the gap looks ginormus.

Re: My door alignment nighmare is here !
 

Not sure what your calling piers...
Did you X brace before you cut out all that stuff?...hindsite is the door should have been hung 1st..

Re: My door alignment nighmare is here !
 

Bottoms of both door jambs front and rear and no bracing.

Re: My door alignment nighmare is here !
 

.I'd start by shimming the bottom hinge..or adj the hinge....the door needs to come up in the back...how does it fit at the top and against the A pillar and front fender?

Re: My door alignment nighmare is here !
 

These body lines need to line up..

Re: My door alignment nighmare is here !
 

How about a picture of the side of the truck so we can see how fit is over all