What had put me off finishing it was difficulty in getting the pillar as stiff as I wanted - with the cover plate self tapped in place I expected this to be rigid, but found that it moved quite noticeably if I lifted the door, due to the flitch panel flexing like an aluminiun can near the top of the pillar. The flitch replacement is the sort with the right angled return back to the door seal and was fully welded into place, so I'm blaming the quality or thickness of the metal.
What I've done today is a bit of a bodge. To stiffen the flitch I've drilled through it and plug welded it to the back of the kidney panel in a couple of places. Problem cured and the door fit is beautiful - but is this approach a total no-no to the more professional restorers out there? Clearly a potential rust trap, but it will be fully Dinitroled.
Sorry, didn't take any photos before I welded the hinge pillar cover in place, but have found one showing the flitch before welding.
Mark[frame]