Will the doors ever stop haunting me?

[rponfick]

I have been working with my doors for some time now, and having a lot of fun. It is truly a journey, and I am looking forward to the destination.

Latest question, has anyone had to shim/build up the inside hinge side of the door? My internal metal frame structural brace does not reach the fiberglass on the hinge side of the door inside. Lacks almost 1/2" on top side on top hinge attachment point on one door. I am afraid to force components together with longer countersink bolts, as I hear fiberglass cracking as I do this. Considered bending steel frame to better fit, but still would not be flush along total length of contact with the door. Currently thinking of maybe building up area on inside of door with shim, or thick layer of bonding adhesive. I already have longer countersink bolts.

The problem does not appear to be in the area at the other end of the structure where the two large carriage bolts attach to the latch plate. The adjustment slots there seem to have plenty of adjustment space left. Although, I am waiting for replacement latch attachment brackets as the ones I have have the opening cable attachment bracket holes 90 degrees off of where they should be. Hint, those of you that have not gotten this far, might want to check your latch bracket plates to see if they match those in the assembly manual.

Any suggestions, or how you addressed the issue if you had something similar, would be appreciated.

Thanks, Ralph