There are several reasons that your passenger door is not fitting very well.
The very first is that the door is bent, and this is the most likely of all
the problems.
Has your car had a door restoration done to it. If not then it probably is
in need of it to get the door steel to fit the birdcage. Remember the door
itself is just 1 piece where the door opening is 11 pieces that form it, and
when
the car was manufactured there was an allowable 1/16 inch variance for the
fit to be called correct. This means that when you figure in stack of
tolerances you have the ability to be 11/16 inch out of whack and still be
called
correct. Kinda scary huh.
As John Blair noted the 2nd reason the door doesnt fit correctly is the
hinges being bent. Recently I have found that not only can the flat part of
the
hinges get bent, but the formed bend in them can be changed as well. I just
recently did a car that had this problem and the particular bend in the hinge
that occurred shifted the door up and in so that when opening it .. it hit the
roof every time when set flush to the roof in the closed position.
As John Blair can attest to, it is not a simple process to fit a Bricklin
door. It generally takes me about 40 hours of solid work to get 1 door correct
at the shop. The best recommendation I can give you is to not go by the door
margins but to look inside the car at the door seal load to know when you have
it aligned properly. This will give you the greatest amount of success
John Lodge
Bricklin Parts & Services
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