Chasing a door gap alignment on a 2020 F-150 for 2 days straight

So I had this 2020 F-150 come in last week, front driver door was sitting proud by like 3mm and rubbing the rocker. I figured it was just a loose hinge, 20 minute job right? Spent the whole first morning adjusting the upper and lower hinges, checked the striker, even swapped the hinge pins. No dice. Turns out the A-pillar itself was tweaked from a prior fender bender that someone already fixed with a cheap filler job. Had to use my pull rack and do a cold straighten, took me almost 8 hours total just on that one door. Has anyone else run into hidden pillar damage that only shows up when you try to set a perfect gap? I usually check for prior repair signs but this one had good paint on the surface, drove me nuts.

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