OK, I left off starting to weld the left cargo door. Sean says he wants a welding tutorial, so this may take some time. Go get something out of the fridge.
Here the weld tacks are growing together into one continuous weld.
Now grind out the weld buggers so it's ready for mud. All the time I'm fitting/welding, I'm constantly opening and closing the door to check the gaps and for interference to make sure the door operates properly. Note the gaps are nice and even.
Let's check the warpage with a straightedge. If you're really good, like Kirk, all you need from here is high-build primer and color.
Not me, I need mud, but not bad, less than 1/8" will smooth this out.
Now size up the inner panel and see how it fits into the floor. So far, so good. Note the red/pink edge of the rocker is even under the panel......
Until you put the lock rod in. Notice the panel is now too far out at the end by the lock rod and the rocker edge disappears. This is going to need some work. I had this issue on Bus 1 also and saw it too late, I ended up cutting the latch plate out of the floor, moving it inboard about 5/8" and re-welding it. I know this is not an unusual problem as I started looking closer at other restored busses and it's not unusual to see the cargo doors "pooched" out at the bottom center where they meet.
It's some kind of production tolerance on the aftermarket parts- they look identical to the OEG but they don't fit right.
Make your pencil marks on the inner panel.
Cut and test fit it in the skin.
Put it all together with the lock rod and it fits like shit.
This little SOB has to come out.