I ended up cutting it, first I added 1/16" from the top to bottom which made the gap between the door much closer to what the other side looks like. Also it was a really tight fit on the inner sill so now it slides over smoothly.

The picture with the screwdriver shows how big a gap there is, it's flush on the other side but I only need to move it 3/16 not 3/8. I cut it along the top edge and took out 1/16" at the back tapering to 3/16" at the front. The door fits flush now except in the center because the door has a curve front to back and the repop sill is dead flat. Some people leave it, others use filler. I will probably use some duraglass to smooth it out.

The fender is sticking out a bit at the back by the sill, it's hitting a little jog on the inner sill that I need to hammer out. I need to patch the fender anyway so I'll sort that out soon. I need to final weld the cuts on the outer sill first and then spot weld it in.

Nice work

Any updates? what been going on? u been very quite.....