I had been thinking about what to do with the door gaps as I still wasn’t happy with them even after chopping them up and extending the frame.
I hung the door properly and did my best to get it to sit evenly. The top hinge didn’t feel right, so I took that back off and set about it with a hammer until it worked properly. With that done the gaps were still big enough to get a horse through, complete with rider.
I finally decided to TIG filler rods onto the edges to close the gaps up, then once I was happy I was pretty close, I went over it all with the MIG to “fill in” the joins between the rods.

After a lot of careful grinding and hand filing I decided it was time to call it a day. It was a lot of work, but there’s not much else you can say about it! The end result is much, much better than it was.

After a good clean with panel wipe and a quick skim of filler the lumps and bumps mostly dissapeared. Needs a bit more work before I call it quits, but I’ll leave it alone till it’s back on the cab now.