with the door open, you can take measurements from the a pillar to b pillar (bottom, middle & top) on the passengers side (side that fits) and compare them to your a & b pillar measurements on the drivers side to see if the gap is the same.
how are your hinge pins? with the door open, grab it at 12 & 6 o'clock and see if there is up & down or fore & aft movement.
have you tried to adjust the 6 large phillips head screws (3 top & 3 bottom on the a pillar) to reduce the binding?
