Postby Launie » 21 Dec 2007 17:50
I've swapped doors from one '76 DHC (now crushed) to the current one, also a '76 DHC, and both had several shims between the hinge and door, clearly factory-installed. Both doors fit the opening terribly - gap at the top (below the gutter) is very large near the back. Nothing suggests the car is twisted. I think it is a build quality issue (are we surprised?).
So to get a somewhat even gap, I'm now shimmed a lot at the bottom hinge and none at the top. But now the handle opening is angled upward toward the back. AGGh! So I'm going to shift it down again somewhat, compromise, and accept some uneven gap at the top.
At least uneven gaps at the leading and back edge of the door can be fixed with some welding rod, then ground back to a nice gap.
Launie