[jsr69]

I need some advice from the many guys who have completed multiple cars and how they have dealt with new weatherstrip.

A little history. The car was completed disassembled and then the body components were all attached and aligned. Gaps were set, and the panels matched. I then began the tedious process of priming and blocking, 5 times to be exact. When it came time to paint, I disasssembled the car again and painted each component separately. Here's where the problem has arose.

Before removing the doors, I drilled dowl holes and installed pins. I rehung the doors after paint back on the dowls and everything went right back into place. All gaps look and the doors shut nice. I started assembling the doors and installed new OER weatherstrip. Now the doors as so frickin tight and I literally have to slam them to get them shut. Here's the bad part, I shut the passenger door so hard that I flexed the sheet metal and cracked the clear and probably a layer of bondo underneath it. Now I've got to repair and repaint the door.

I can't believe I'm the first to run into this problem. So here's my question, what are other guys doing to address this problem. Any suggestions would be greatly appreciated.