Thanks for the suggestions. I placed seven washers between the body & mount.
The door will close now, but it's not a "perfect" fit. I suppose it will get
me through the winter though, and in the spring I can fix it properly.

If anyone is interested, I think I know where I went wrong. I took the jeep
apart down to the frame. The section of the frame in need of repair was best
fixed with the tub off. While the tub was off I figured I'd fix the problem
rust areas. One of the more extensive areas was the driver's side floor
(almost non-existent!) and the side immediately in front of the door. I cut
out the bad sections, then cleaned the surface rust with a wire wheel. After
the rust was removed I welded in new metal, did the filler thing and
primed/painted. What I believe I may have done is moved the tub with the
floor / side section removed thus changing the dimensions of the opening.
welding the new floor in sealed the deal!

In retrospect I should have tacked in a piece of angle iron to keep the
opening from changing.

Thanks again for the suggestions!

Doug

 

A tree fell on my '93 YJ and bent the tub, and I ended up with about
your problem. I put the base of a hi-lift between the lower roll bar
mount point at the floor behind the seat, and the lifting jaw against
the dash with a 2x4 to protect the dash. Then I just cranket it to get
the right distance hinge to latch. The bottom of the tub was wrinkled
too, so I straightened it the best I could with hammers, then got new 6"
tall rocker guards (A2Zfab) to hide the wrinkles. Cost $1000 to buy
used hood, fender, grill, have them painted, and the rocker guards. Ins
co paid $3000 for the damage, cool. Added and 8.8 and new Swampers for
the extra cash.

 

A tree fell on my '93 YJ and bent the tub, and I ended up with about
your problem. I put the base of a hi-lift between the lower roll bar
mount point at the floor behind the seat, and the lifting jaw against
the dash with a 2x4 to protect the dash. Then I just cranket it to get
the right distance hinge to latch. The bottom of the tub was wrinkled
too, so I straightened it the best I could with hammers, then got new 6"
tall rocker guards (A2Zfab) to hide the wrinkles. Cost $1000 to buy
used hood, fender, grill, have them painted, and the rocker guards. Ins
co paid $3000 for the damage, cool. Added and 8.8 and new Swampers for
the extra cash.