I finally got the door down out of the loft to fit on the door pillar I made from scratch. I discover that the rocker panel does not fit as I expected, as the body line slips up under the edge of the door. I may have to cut the aftermarket panel and add some metal to drop it down below the door. I am now worried about the other side already finished.
The bottom of the fend stick out too so I will have to trim back part of the floor. The floor was completely rotten and I thought I kept it within close specs. however that black fender is not original to the car, it may also be aftermarket. I could easily trim back the bottom of the fender to make it fit properly. I will do that after the door is properly aligned and the pillar is welded into place.
Tonight I cleaned up the welds that had pin holes in the welds and cleaned the metal before spraying it with copper weld through primer on the back, I may tape off the contact points then topcoat the inside with rust proof paint.
I am using copper weld through primer because the zinc version causes a lot of spatter and smoke. I am not sure zinc works very well. The top of the picture you can see the remains of the old rocker panel, most of this will be cut off and the rocker will be welded to the remaining short piece.
