Ok, I went back to the riders door and checked it again. It opens and closes well, no rubbing. When closed and latched, the reveal around the door is pretty good. Because of the problem with the drivers door I checked the upper window frame.
IMG_2191 by
Robert Moorman, on Flickr
The top back is 1/4" in at the curve. So I checked the front.
IMG_2192 by
Robert Moorman, on Flickr
It is almost dead on all the way.
So I did as Joe suggested, used a block of wood and slowly moved the upper channel out so it doesn't rub. I put in the latch and latched it and this is what I have.
IMG_2193 by
Robert Moorman, on Flickr
It's 3/8" IN at the front upper curve. It is almost dead on at the rear upper curve. I'm worried that when I put the weather stripping in it will not close.
Also, at the belt the door seems to be in about 3/8" as compared to the cab. I guess this could be a hinge thing, but I'm looking for some help here. Any ideas?
So I started on the dash. I've shown the dash work before, and I showed how the cut it out, here it is again.
IMG_2194 by
Robert Moorman, on Flickr
So now I'm removing the last of the old dash from the bad cab to "build a new dash that can be spot welded into the cab.
IMG_2195 by
Robert Moorman, on Flickr
Cutting spot welds out of the dash is a PITA! I am trying not to bend up the flange, but I can already tell I'm going to be working on the dash for a while.