[Vic1947]

From here it was just a matter of tacking the flange in place and then piecing in sheetmetal to fill the gaping holes. Welding and grinding has produced surfaces on the door and jamb that will only require a small amount of body filler.

It was now time to see how the door worked, so I bolted it to the hinge swing arm. Good thing I'd used the washers as shims because the door was too far forward. I removed the washers and the lower bolt hole spacer and reinstalled the bolts. Success at last! The door gaps looked pretty decent and the door opened nice and level. At the moment there's a tiny bit of droop (~1/16") at the top front edge of the door frame. I believe the latch will fix that easily, and if not, I can put a thin shim at the hinge to lift it. I'll wait until I have the latch and power window in place to make a decision on that.

My main goal was to check clearances and see how the door swings. All that looks good at this point.