Anyway spent most of today getting the door to fit better, and I got one more bolt in so that's 5 of 6, couldn't get the last in for love nor money so it's staying out until the resto. I had 5 bolts in but the door still was about 10mm too low at the back, had to loosen the bolts holding the hinges to the pillar and lever hinges up with a crowbar whilst tightening bolts down to bring the rear up again. Still not perfect but good enough, just have to close the door a bit harder or close it halfway then nudge it shut.
After that I did the wing mirror which was easier than I thought; took measurements from the dud door and transferred them to the new one and drilled 2 holes. I was so close I drilled through the blank captive nuts on the other side, pity I didn't have a tap set to cut a thread in them. I just drilled through them and also the thicker inner skin to use a nut and bolt, trimming the bolt down so it didn't foul the glass. Only downside is now to take the wing mirror off the glass has to come out
I will probably end up welding the nuts to the inside one day. Glass didn't need any adjustment by the way, seals nice and snug against the rubber. That was all the hard part done so then it was a matter of replacing all the interior, front guard and cowl panel. Now it's all done! I definitely have inconsistent panel gaps around it but I don't care, if it doesn't leak I'll be happy. Also the paint is a slightly different shade (less faded) than the old paint, and the bumper strip is wider with chrome on it which looks a bit odd.
still sucks that it happened.
