Spent more hours on getting the shape of the extension bit better and smoother. Welded the second B pillar to it. Will weld that to the original B pillar and floor later in case I need to adjust it.
I made sure the the pillar matched the door back edge when square to the sill.
Knowing how much to cut off the other part of the door was just a matter of measuring the gap.
I didn't take off anything for the door gap so I had 3mm-1/8" adjustment to get good alignment. Here it sits straight after the first cut.
The extension piece is just sitting on the sill without the gap needed so why it is bit low. But can see that I will need to do something about the top opening in the panel.
It had a dimple right where I need it to be flat so raised that first. Then got a piece of scrap the right thickness to match the step around the hole. Welded that onto a thicker piece to hammer against.
Clamped it into place and supported the bottom of the vice grip and also the door skin to free up a hand.
Just hit down with a brickies bolter to set the form I needed.
Step nows extends to the end and just needs a bit of planishing and trimming.
Both sides done now.
All lines up pretty well considering these two parts of door came off the production line 10 years apart.
I think the shorter door and wider pillar looks better. So the door is 115mm-4.5" wider than stock and the B pillar 60mm-2.5" wider.
Ribs line up pretty well but there will be plenty of work to get it all sitting just right after welding.