Posted by Glen of Idaho [172.68.34.55] on Thursday, May 23, 2019 at 10:16:10 :
I solved the door latch mystery. If the top of the adjustable frame latch is worn off it changes the point of contact on the star wheel in the door latch.
Rebuilding the drivers side to match the passenger side dimensions allowed the frame latch to hit the star wheel right allowing it to rotate correctly and lock.
You did a nice job of rebuilding the door latch. I should have taken you up on the other part.