Door fitment and new metal replaced need help

[Navy_chief]

Ok,
guys here is the situation. Have completely replaced all the sheet metal on the passenger side new shocks new radius arm bushings and new cab mounts.

The passenger side is still not allowing the door to line up right?

Now the drivers side has a really bad floor pan and door/post pillars as well and when you look at the front of the bronco you can see the body is noticably sagging on the drivers side.

We placed a ram on passenger side and jacked up the cowl area abit seem to help the door and fender body lines now line up, however the front of the door is still hitting near the top of the roof near the windshield area.

So should we go ahead and cut out the drivers side rotted panels and then attempt to line up the doors on both sides once this has been done?

This is really frustrating oh we have not tied up all the new metal on the passenger side just the floor pans and the inner rocker and just tacked up the door hinge pillar post not permanet?

Any help would be greatly appreciated

 

[rustbucket]

I hope you're working with fresh body mounts. If not, you're never going to get it to line up right. Did you brace the body at all before you cut out all that metal? The hard top won't be much help, as there is a hinge on the bottom. Even if you tighten the bolts, there will still be flex.

 

[sellitall]

Just like rustbucket said having good bodymounts will be key in getting lined up. I suggest purchasing a brand new bodymount kit. I have also posted the chart another CB member did some years back to help you out.

Do one side at a time. Keeping it on the frame will also help you since the rotisserie can deceive you. That happened on my last build. I thought my lines were good, but when I bolted it to the frame it was out by a pretty considerable amount.

 

[Navy_chief]

I hope you're working with fresh body mounts. If not, you're never going to get it to line up right. Did you brace the body at all before you cut out all that metal? The hard top won't be much help, as there is a hinge on the bottom. Even if you tighten the bolts, there will still be flex.

The body mounts on the frame are rock solid. Yes we did brace the body and looking at the diagram shown above with the measurements everything lined up preety close as shown. We tried to ovelap the metal on a few spots about an 1/8" but have since cut those loose to get the body to flex mor for better fitment.

Which did get the door to line up with the qtr panel and the fender but it is still about a 1/2" off at the very front of the door where it meets the roof?

Hence should we start cutting out the drivers side rust and replacing the floorpan and the rest to build it up and level the body out because as stated when you look at the front of the Bronco the driverside is sloped down due to the rust in the rocker and floor pan?

 

[Explorer]

Think your problem is going to be in the F-G measurement. Notice how much the measurement changes for different years.

 

[Navy_chief]

Is there a diagram showing the passenger side measurements or just use these shown on the drivers side?