After a little tweaking with a sander and Dremel grinding wheel, we mounted the door cards to the doors with 10-32 nutserts. The right door card fit well, but the left one needed to be modified. The top rear corner had a 5/8” gap from the door. After determining where the door card started to pull away from the door, we cut it into two pieces. Both pieces were sanded on the front and back to prepare them to be epoxied. Clear packing tape was placed under the cut line to prevent the epoxy from sticking to the door, the small piece was held in place with a temporary screw, and epoxy was mixed with mirco balloons to a peanut-butter consistency. The mixture was pressed into the cut line with a wood tongue depressor and after it kicked the door card was removed, the seam was sanded smooth and fiberglass cloth was added to the backside. Problem solved.
The next step is to validate that door cards clear the removeable side impact bars.
Door card cut and about to be epoxied