Last night i removed the a-post skin and took a look at the a-post alignment. With some help and measurements from Guy Weller on the MG BBS i found that the bottom of the a-post was an amazing 1/2" out! It should measure roughly 17 3/4" from the tip of the sill, mine was 17 1/4"! This explains why the door was catching on the lower rear and why it needed lifting a little to fully engage the latch.

Fortunately i was able to fix it by widening the mounting holes on the door allowing it to be adjusted further on the lower hinge. Its not ideal, but it seems to have worked. I then made up some small patches to create the a-post to scuttle gusset. This was welded up with the door closed and the gaps correct to lock it in place. The door now closes smoothly and lings up well. The gaps could be smaller, but nothing is perfect is it!

I trial fitted the screen to make sure my fabrication would not disrupt it, with a little trimming the screen frame slid in perfectly. The patches need grinding smooth and preparing prior to fitting the another new a-post skin.

The new a-post skin will need to be carefully positioned to take out the 1/2" misalignment, but this should be do-able as the door is straight and referencing a wing will ensure it all works out, hopefully!

When fitting the last a-post skin i had problems folding the flange around the a-post. Ive been advised that using some wood to spread the load will avoid any distortion in the skin.