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So the issue that I was afraid of finally cropped up. I have replaced my engine bay aprons and one shock tower in my 67 cat, as well as the front radiater support, strut rod frame members, frame rails, and driver floor and torque box as well as removed and replaced the cowl cover to replace one of the cowl hats. I took measurements beforehand up front and continued to take measurements during the work, including test fitting the quarter panels after each panel replacement. The panels fit just about right till the end of the work to the front of the cougar.
The issue is with the driver side front quarter panel. Below is a pic of the front inner edge prior to removing for restoration, notice the front mounting hole and edge at front support:
In the pick below, I test fit the panels after reinstalling the cowl cover. Mounting holes lined up and the gap by the window was acceptable.
The next item I replaced after the above work and pic was the installation of the driver torque box and floor pan and installation of the right rear engine bay apron. These were the last two items to be replaced up front.
Now notice the front mounting hole:
Here is the entire quarter panel:
And no gap at the back:
I am trying to figure out what occurred after the cowl was reinstalled and installation of the driver torque box and installation of the right rear engine bay apron that could cause this to change so drastically. Comparted to my measurements before and after the work noted above, the whole assembly is about 3/8" or slightly more off from previous measurement.
This is extremely frustrating as I was taking care during each panel replacement to check measurements before, during, and after installations to avoid exactly this issue. I know that this cougar was hit pretty good on the passenger side up front sometime in its past, so I am wondering if it is possible that I released some frame torque or something that is pushing things out of alignment, but I just can't figure what changed.
Any suggestions would be greatly appreciated.
The issue is with the driver side front quarter panel. Below is a pic of the front inner edge prior to removing for restoration, notice the front mounting hole and edge at front support:

In the pick below, I test fit the panels after reinstalling the cowl cover. Mounting holes lined up and the gap by the window was acceptable.

The next item I replaced after the above work and pic was the installation of the driver torque box and floor pan and installation of the right rear engine bay apron. These were the last two items to be replaced up front.
Now notice the front mounting hole:

Here is the entire quarter panel:

And no gap at the back:

I am trying to figure out what occurred after the cowl was reinstalled and installation of the driver torque box and installation of the right rear engine bay apron that could cause this to change so drastically. Comparted to my measurements before and after the work noted above, the whole assembly is about 3/8" or slightly more off from previous measurement.
This is extremely frustrating as I was taking care during each panel replacement to check measurements before, during, and after installations to avoid exactly this issue. I know that this cougar was hit pretty good on the passenger side up front sometime in its past, so I am wondering if it is possible that I released some frame torque or something that is pushing things out of alignment, but I just can't figure what changed.
Any suggestions would be greatly appreciated.