Got the driver's side mostly done this weekend. Need to finish up the pinch weld under the outer rocker and grind everything smooth. I decided to not let perfection get in the way of done - I have no intention of ever putting real money into paint on this truck, and I find inconsistent door gaps to be charming. I drilled 1/8" holes through the hinges into the a-pillar so I could get the door back to where it was and hung the fender back on it and things seemed to line up like they did before. I was pretty frustrated when I put the new rocker up and saw a big mismatch to the inner rocker, but I found where a few guys have pie-cut the front end cap of the outer rocker to bring up the bottom to match the inner rocker. I did the same and it turned out fine. And i doused everything in self-etch primer
Old junk:
New stuff:
I think i'lll do the inner door bottom next while I have it all apart.