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never had problems taking on and off my door panels and there being any gaps. But have always kept in mind to make sure all pop clips are there and intact.
what helped me earlier on to make sure each clip was popped properly back in was to take small pieces of masking tape and stick them on the opposite side of where each clip should be. that way i'd know which exact spots to PUNCH..er I mean, pop back into place.
also making sure the top edge of the panel is hanging properly off of the top of the door? making sure wires aren't in the way? what were you doing that required you to take off your door cards?
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