Welcome Drew.
That all sounds very drastic. The door alignment is via slotted holes in the A and B pillars where the hinges bolt on and in the striker plates. There's a good (almost) 2cm of play in the pillar slots and the strikers should be shimmed if needed. I had to adjust the doors on mine in order to fit the checker plate to the sills.
The gap between door and A/B/C-pillar and to the sill is 7-11mm with the gap between roof and door of 5-9mm. This is the with a tolerance of +/-2mm to parallel with the sill.
There's a lot of tolerance allowed in a Defenders panels...
MY15 Discovery 4 SE SDV6
Past: 97 D1 Tdi, 03 D2a Td5, 08 Kimberley Kamper, 08 Defender 110 TDCi, 99 Defender 110 300Tdi[/SIZE]
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