It's been a while since I could work on the LeMans, I got covered up with computers to repair, recover data etc. After the storms hit I had 14 computers which took first priority for my time. (I'm self employed and own 2 companies)
I have spent about a day attempting the align the doors and fenders. Part of my problem is I don't know what the gaps were since the fenders and hood had been removed and when reinstalled no shims were replaced and the bolts were finger tight. I can't find any gap information in the service manual, maybe it's there and I missed it. I also suck when it comes to panel alignment and it probably doesn't help that I have to work alone. It looks like panel alignment is really a 2 person job. I will post some pictures in the 68-69 section asking for opinions a little later when I can get some time.
I went to install the hood on and found the hood hinges I have are wrong. The hood sits up about 2 inches in the back with the hinge at the lowest position in the slot. I ended up reinstalling the old factory hinges so I can check hood gaps, right now it looks like I would end up with about 1/8" gap. I don't know it this is enough.
It's starting to look more like a car again.
I don't know how normal this is but when everything else looks like its aligned good, the gap grows from 3/16" to 1/4" at the top of the fender where it meets the door. Assuming that this is not a screw up on my part, I guess the door or fender would need the be welded to fill this gap.
So far I have identified about a dozen items that need attention a partial list includes
1. Rework the top corner of the rear quarter panel where it meets the door
2. There is still some straighting to do on the driver fender inner bracing.
3. Passenger fender at the very bottom does not match very well to the rocker panel. This was caused by the patch panel not being formed correctly.
4. Driver fender patch panel does not match the contour of the door near the bottom. It did however match the rocker panel.
5 to ? other minor items to deal with not worth listing here.