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Had exactly the same issue on a Crayford we are restoring. Heritage inner wings with M-machine outer A panels. Problem is with the inner wing as everything else lines up perfectly. Same combo used on R/H side and fit was perfect. We were replacing the A pillar closing panels so that gave enough access to massage the wing to the A panel and work our way up getting some decent mig tacks on. Was no way the panel would pull together for spot welding without surgery.

Thanks that makes me feel a lot better, think I will cut off the return on inner wing and make a piece to move it to correct position, it's easy at moment as I can just remove the inner wing again to weld it, I can then spotweld the flange to outer panel as std. My electrodes on spotwelder will just do it if I insulate some areas on panel. Thanks again

Darren

Hopefully if everything goes according to plan should be easier on the other side by sounds of it

I had the same issue on with my mk2, just cut and added a strip like previously mentioned

Well thanks for that as it really does put my mind at rest now, I will refit door and tighten hinges to be sure then alter the inner wing to suit, hopefully drivers side will be less hassle.
I just didn't expect this with a heritage panel as I thought they were from original tools

maybe its because the heritage panels are modified mk4 internal hindge aren't they?
its difficult to measure but let me know if you want another measurement

thanks,

cant measure mine till end of the week but will post up findings as it may help others.

Darren

Done a few checks and am now 100% positive I need to alter the panel as everything else is spot on,

I made a template to shape I need to alter to, should get it modified the weekend so will post up the results, but thanks all for the information

Just to finish off the update I welded a piece in, didn't fully grind it down as once inner a panel in place won't be seen at all, I didn't want to weaken it too much.



Then trial fitted inner a panel all ok so started welding inner wing in, hopefully finish off next time,



Thanks for the advice on this and hopefully I will find other side easier

Darren

Glad you got it sorted. Just a shame that the extra hassle was necessary.
I believe the offside inners are a better fit.

Nice work! Like you say it's hidden and will never be seen so just peace of mind that you have made a strong and long lasting repair. It's just a shame that this happens when you are going to the effort of doing a proper job with the supposedly "correct" panels.