Door post alignment???

[Bronco Paul]

Ok...so I'm replacing the door post, inner kick panel, inner rocker panel, outer rocker panel, and then the floor board. I've jacked up the dash to get everything to match up the measurements...

I've lined everything up according to the chart...I used the 71 sport measurements.

Made sure that the inner kick panel lined up square to the cowl.

But there little things that aren't lining up like the inner fender to the inner kick panel at the top.

...the door post doesn't match up flush with the inner kick panel and there's a gap between them at the edge so they don't sit flush to oneanother.

...the outer rocker panel dosen't mount up flush with the quarter panel at the bottom.

...and the roof doesn't sit on the quarter panels anymore.

Now if I let down the jack the measurements are off on the distance from the top screw hole on the door post and the floor and the inner kick panel isn't square to the cowl...but most of the problems go away. Has anyone else had this problem? Any ideas on how to fix this???

 

[wesleydax]

its a combination of things. the new metal, where is it made? if it was made from old dies the tolerances are off. did you take mesurements before cuting everything out. its not going to just fit, your gonna need to persuade it to fit. make sure the door fits and go from there.

 

[DuctTape]

I was doing same thing (pans, rockers, kick panels, inner fenders, floor channel, front posts, fenders) and had a bunch of little fitment problems on pass side after I got drivers side tacked down. Could not figure it out so I took it to a pro. He told me he tweaked using washers as shims under the body mounts.

One thing I can tell you for sure is mock up everything before breaking out the welder.

 

[Bronco Paul]

yeah...I spent the whole day doing that. I figure I'll find the best fit and go from there. I'm just trying not to get to the end and have one giant mess!

 

[wesleydax]

make sure you have good door fitment and go from there. if the door fits the opening you can work the rest from there. ive spent a lot of time reworking new metal. it just dont fit right with out a little persuading.

 

[azreddog]

I am in the middle of doing the same thing on my sons 71 bronco. We replaced both hinge posts, kick panels, floor,rocker panels and rear quarter panels. We finally have one side all welded up and everything lines up perfect.

We fit everything several times and attached with sheet metal screws. we still had all kinds of fitment issues. Then we attached the hard top to the body and the windshield. We then squared everything up and STILL HAD TO SHIM THE BODY MOUNTS WITH WASHERS TO GET EVERYTHING LINED UP. one side is all welded other than the rocker panel. This was a lot more work than what I had anticipated.

I can tell you this tested my patients several times. I had to send my 16 year old son in the house one day because I was so frustrated I wanted to put my fist through the wall.

Even with the frustration I am still enjoying the time I am spending doing this with my son. I think it will be worth it in the end.

 

[Bronco Paul]

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Just an update...
I sent back the pos(Best...OEM quality) rocker and got one from Wild Horse...it fit first time in! All the measurements lined up and now it's a permanent part of the Bronco! I spent over a month taking measurements, clamping on, and retaking measurements on that crappy rocker panel...I had a few people message me and told me they were having the same problems...solution...ditch that crappy panel and get one that fits!!!

 

[Mill KNOB]

Great that you got the door post work out.

So what vendor did you get all the sheet metal from that didn't fit?

 

[Bronco Paul]

lol...yeah...I had that posted and someone from the company contacted me and asked me to remove their name! I'm sure they just searched the name and it brought up all of the posts with their name...so...until I spend my store credit let's just say it was some guy with some bronco parts! I can tell you that the ones that fit were from Wild Horses 4X4.