After several attempts over the past couple days, still no success getting the driver side door fit. Sorry no pictures but it was too frustrating to pick up the camera. It's becoming increasingly more evident that at some point the cab has been put out of alignment and no amount of adjusting hinges is going to get the job done. Current theory is that when the truck sat and the floors and sills rusted through the cab lost it's shape and the patches that were welded in just held it in that position.

The plan now is to remove the remaining floor patches to eliminate anything that might be holding the cab in its current state and then start jacking the cab to get the door opening the correct size and shape.