After tacking in the upper rod across the top I started with a piece of 1/4 in and about half way down changed to 3/16th due to the gap being more narrow as I got closer to the bottom of the door.
This is the 1/4 in. after bending to fit upper back curve of door gap. You can see how close it fit but like I mentioned had to change to 3/16th about half way down.
This is the rear gap of door. At the bottom you can see the bend I made after tacking down the 3/16th rod to that point. Would have been very difficult to get this right using sheetmetal.
Welds look worse than they are because of the burnt primer. Ran an abrasive wheel on a die grinder along the very inside edge of gap only. Also cooled with a damp cloth after every other tack all the way around to reduce any chance of warping the body sheetmetal and so far it doesn't look like I'll have that problem.
That's it for today and plan on grinding welds tomorrow and smoothing out with filler and prime.
98 Safari RWD. Stock.
