I had previously attached the inner a-post and aligned the door as best i could. Sunday morning i decided to tackle the a-post skin an make the hinge pillar complete.
I stated by placing the skin over the a-post and making some visual checks. It all seemed well, so i removed the door in order to clamp, mark and cut the a-post skin to make it fit. Once trimmed and trial fitted i drilled several 8mm holes (using the new pillar drill) along the flange to allow plug welding in place.
Once "dry" fitted again and clamped, folded the door side flange around the inner a-post and squashed tight using a set of "mole" grips. I tacked the remaining flange to the foot well and re hung the door.
Something is not quite right! The door catches on the front of the a-post cover. I have adjusted the hell out of the hinges and catch plate, but nothing gets it clear. On top of this the door requires a little lift to fully close on the catch
In an attempt to rectify the catching issue i trimmed some metal from the a-post skin. This gave the required clearance but doesn't look good! I would need some filler and some smoothing out to make the vertical lines straight.
I need to address the door closing issue, I'm not happy about lifting it to close, it should close with a nice thud and with no need to lift it.
I may have to remove the a-post and skin and start again. Its not impossible but just a nuisance.
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