This does not surprise me in the slightest.
I was expecting it when it came time to test fit the door after a very significant amount of new steel plating had been applied to the front cab corner of the '56. If you go back through the blog, I am sure I have added some photos of just how bad that section was. When I first saw it I was in a state of disbelief. In fact, I don't think the magnitude of the damage hit home until after the new steel started replacing the rotten stuff. Peter (and to a lesser degree, myself) cut and welded some substantial pieces of plating in that area. I replaced the entire rocker panel on that side as well as a brand new pillar. (I already had a pillar piece, but it didn't come with the hinge, and then I saw that they made a piece with the hinge already incorporated, I lashed out and bough one). This was a godsend as it saved a hell of a lot of work (none of which I have the skills for).
So, we got stuck into repairing the side, and I must say, I think it came out really well all things considered. The proof of the pudding was in the fitting of the door...
And wouldn't you know it? It didn't fit. Had no intentions of fitting. I have to say, it is near impossible for me to get down and investigate why the door is not closing as the truck is almost hard up against the brick wall of our garage, but it hasn't stopped me formulating theories, and here are a couple:
We aligned the new piece of pillar to the original pillar. It only makes sense. Or, rather, I thought it did. But now I am wondering whether the truck has a natural taper, as the door seems to hit a rock about an inch from shutting, and all the issues seem to be concerned with that corner. You can see here we welded the new piece of pillar to the new rocker panel , and now I am thinking that is not such a great idea as there is no flexibility whatsoever. That is, if I wanted to get the rocker panel to come in more, I really can't because it's welded up solid.
The solution might be to grind out that weld and try to bring the whole pillar a touch inward, or perhaps just some re working of the rocker panel might be all that is required.
