I didn't have a hard time getting my door lined back up when I put it back on, maybe I was lucky. I also had a helper and only had to tinker with the adjustment a couple times to get it back to just the right spot. I can imagine trying to do it by yourself.... those doors aren't light! I would defiantely remove all the vacuum lines before doing any welding unless you want to be replacing them.

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1985 300D Turbo ~225k
2000 F350 (Powerstroke) 4X4, SWB, CC, SRW, 6spd ~148k
1999 International 4900, DT466e (250hp/660 ft/lbs), Allison MD3060 ~73k