Even though there was progress, I don't really have a lot to explain or say. It was a day filled with many iterative fittings and measurements and what-not to make sure that I didn't repeat the problems I made for myself on the driver's side on the passenger's side. I'm confident that I did not.
What is boiled down to (the video gives a better view of the process) was fitting up the pieces, locking them in with vise grips, and making marks. I ended up cutting down the bottom of the new lower A post piece by about 1/2". I was really leery about doing this, but the support inside of the upper A post only went up so far, so I was pretty confident it was correct.
Once I was happy with the fit, I locked it in with vise grips and plug welded the corners. I had my son with me today, so I let him finish the job (which you can see in the video).
|And in. Still need to do interior portion.|
|The plug welds for the inner supports in the upper A post. Not pretty, but they should hold.|
|Interior welds yet to be done.|
Realize that fitting the lower A post was not done in a vacuum. I went as far as to fit the entire sill assembly (inner, strengthener and outer sills), fitting the door and verifying measurements. It wasn't perfect, but it'll do.
|Marks on the outer sill to ensure I get back to this point when I'm ready to weld it in.|
This process literally took me 4 hours. Yes, four! Like I said, I'm a bit gun-shy now with making sure everything fits properly, so I wanted to be extra sure. But, with that done, and with limited time left before a soccer game, I revisited the driver's side door.
In short, I made no progress. It still fits as poorly as before, but I wanted the extra set of hands to help me maneuver it just to be sure. I'm still not positive what I'm going to do on this side...
|Still minimal gap at the bottom. Frustrating.|
That was about it for the day. Again, the video gives a better account of what all we did, but it is what it is.