Smoothed off. You barely notice the extra couple of millimetres to clear the window channel as I made sure the folded edge was still straight and inline with the rest of the door. Here you can see the differences and the modifications needed. I hammered out the old recess for the exterior handle mounting screw and also deepened the one side of the pocket for the window channel mount.


I had done this by making this little hammer form to match the shape I wanted in the end. The form was placed on the table and the door clamped over it. The edge was then hammered down. A mallet was also used inside the door to hit down on top of this hammer.


Can see the shape finished now. Can't say I was that rapt in the way it mounts with the jaws protruding past the door edge when open.


It also meant the striker bolt mount would be partially off the edge as well on the B pillar as well as the caged nut on the back. So I welded up the mounting holes and made the front opening hole smaller as well. Moved the whole lock back further inside the door. This also solved the clearance problem with the locking lever as well as more clearance for the opening and closing release latch as well.


I couldn't use the recess as then the striker bolt would not reach the new lock. So it was cut out completely so that the new mounting plate with the nut cage with nut could be butt welded into place. The top and bottom edges were arched outwards slightly so that the weld shrinkage would pull it inwards.