Falcon,
Do you have any pics showing the bad fit of the door before the repair? What size portapower did you use? When I was building my 34 for the first time 46+ years ago I suspected it had been in a role over. The drip flare on the drivers side wasn't as defined as it was on the pass. side, the hinges had to be forced to get the hinge pins to fit and the door never fit right. In this present rebuild I discovered that the rocker panel on the drivers side had been replaced and was done poorly as well. This time around I am cleaning up the original repair by cleaning up the welds on the rocker panel and using the portapower to force the lower body to better fit the door. Sorry to ramble on but we seem to have similar problems. It looks like you are doing a good job on your repair and it looks like my body will be off and on several more times before this is over. Keep up the good work. Jack.