Teardrops n Tiny Travel Trailers

My hatch frame was hitting one wall with the temporary install. I thought it must be warped even though it measured equally from corners and thought I could maybe pull it straight with the sheet metal covering. The metal was square (5’x4’) and measured equal overhang with the frame when installed so I thought it would work. Now it hit’s the wall before it is even half closed! The walls are reasonably square and the hinge ends appears to be equidistant to the floor (square/level).
Another problem is that, despite my best efforts of installing with ¼” gap between the hatch and roof spar at the hinge, final gap is now more like ½”. Now the hatch has to be shortened. I am using the McMasters plastic hinge and wonder if it stretches.
I am afraid to remove (60 screws total and set caulk) as the screws will not purchase as tightly when reinstalled and I am pretty fixed with screw hole location.
Any suggestions? Right now I have it propped on one corner with weight on the other.
Sorry no pics. Not electronically sophisticated enough to go from camera to computer to this post.

I'm having a bit of a hard time picturing what is going on. On my Benroy build, I also had the hatch frame rubbing due to being slightly out of square. My solution was to get out the belt sander and remove some of the offending frame. If there's not enough clearance (sheet metal gets in the way) you could also use a top bearing bit (bearing near the collet end of the router) and temporarily screw down 1/4" plywood to use as a template. Hope this makes sense.

...you say "walls reasonably square"...uhm what constitutes "reasonable"...it is kinda hard without pics but it seems as if a couple of possible things...
...first, the body has to be square and plumb with each other...that means both height and LENGTH...a perfectly square hatch will not fit in a hatch opening that is out of kilter...
...second, a bad hatch...you say it measure the same corner to corner...did the ply lay flat/even/square on the hatch...alternately, did the arc/shape of the spars change after cutting(can happen)...are you a victim of the dreaded "spring back, where the underlayment tries to pull the spars out of shape...and finally, were they accurate to begin with(not bustin' your chops...just askin').........
...those are someplaces to look for the answer to...WHY...figure that one out and you'll have way to a fix!!!!!!!
madjack

OH... that dreaded word "springback" it scared me to death doing mine, then sure enough, the hatch went to go on the body and of course seemed like it was warped wayyyy out of kink... I just about threw it out back of the yard and started wondering why in the *(!#* did ever think I could do this ? what the 7734 was I thinking !!!!

Luckily my helping neighbor friend who knows wood and cabinets, he came down and said it's wood, let's fit it in where it should be and we clamped it to death and let it sit for a few days... just to MAKE it take shape.... didn't spray it with water or anything... but wahlah!!! it worked...

Can't describe it any better or have pics but hopefully you'll get it back where it needs to be...

We've ALL been there!!!!