I suppose the obvious questions are:-

(am assuming hinges and hing pins are in good order and no slop / wear present.)

1. did the door fit correctly before you started replacing metal / sills.

2. did you brace the door frame before cutting and fitting new sill-work

3. did you remove the body from the chassis to work on it.

4. if you did remove body from chassis to work on, did you brace it against distortion.

5. how much gap do you have between edge of door and 'A' post.

6. how much excess width of door do you need to accommodate.

There are 'tricks' involving hinge bending but in my opinion these are only used for fine tuning gaps / alignment and only used when other options have been followed.

Steve V.

Location: Polegate, East Sussex, United Kingdom