I'm making good progress on the metalwork of my May 1971 240Z.  But when I rehung the right fender and door, I simply could not get the gaps acceptable.

Here is a pic of the car before stripping and disassembly.  I can live with these factory gaps.

After stripping and epoxying, the door still fits with all the body lines aligning nicely.

But now the front gap is much larger than original.

Of most concern is this:

The vertical gap at the lower corner of the door is a whopping 11mm wide!

Now my first thought was that the fender was simply not aft enough.  But the lower shirt of the fender is up against the the little jog in the rocker (so it sits nice and flush) and the screw holes at the cowl are maxed out. So the fender is aft as far as it can go.

So just what the heck is going on here?

 

 

I don't know what's going on but you could add to the front edge of the door if you can't come up with another solution.