Had a customer call me out on my door gap alignment last Tuesday

I was finishing up a driver side door on a 2018 F-150 here in Phoenix and thought the gap looked pretty good. The customer walked up and pointed out the bottom was a hair tighter than the top, maybe 2 millimeters difference. I didn't see it at first but he was right. So I spent an extra 45 minutes loosening the hinges and shimming the bottom bracket to get it even. Totally changed how I check gaps now, I use a feeler gauge at three points instead of just eyeballing it. Has anyone else had a customer spot something you completely missed?

3 comments

3 Comments

stella2215d ago

2mm on a Ford truck door? I'd call that a win, not a miss. Those things are built like tanks, you're lucky if they don't look like a 5mm gap on a good day.

kai_chen215d ago

Are Ford doors just worse than Chevy's or is this normal?

mileslane15d ago

Yeah, "built like tanks" is exactly right. I had an old F-150 from the early 2000s and the driver's door gap was a solid 4mm from the factory. Never changed in ten years of ownership. My buddy's Chevy Silverado from the same era had tighter gaps but the hinges started sagging after a few winters. I'd rather have a consistent 2mm gap that stays that way than a perfect 1mm gap that turns into a mess. In my experience, Ford prioritizes toughness over perfect panel fit. It's just how they're made. Take it for what it is.

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