Rocket,
These comments may sound a bit simple-minded, so if you have already gotten past these issues, then please disregard. But...
Did the door fit properly before you disassembled? These dash pieces have quite a bit of play, they need to be carefully aligned. If you renewed the leather box lining, then everthing will be out of whack. The screws (hidden behind the leather) need to be nearly flush, both top and bottom, or they will restrict closure. The keeper nut on the light switch must be on the right way and completely tight. And lastly, if you had any reason to disassemble the locking mechanism make sure the tang (the thing I think you were adjusting by bending)is on properly. Once you have all that straight you will have to take it apart and reassemble, from the bottom bolster up, to get everything to look staight.
Hope this helps,
g
'64 230sl, fully sorted out...ooops, spoke too soon