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During the early C3 period, GM apparently had some "big time" problems getting the Corvette's door hinges right. From 1968 through 1973 there were a total of FIVE different sets of upper door hinges used in PRODUCTION on Corvettes and two different sets of lower hinges used in PRODUCTION even though the doors and birdcage changed very little during this period. 1968, alone, used 2 different sets of upper hinges. Very early used GM #3915707 and 3915708 and later used GM #3935609 and 3935610. The latter were also used for early 1969 before being replaced by another set of part numbers.
The lower hinges were used throughout the 1968-69 period and were GM #3915701 and 3915702. They were replaced for 1970 and later, though.
The hinges you likely purchased are GM #327627 and 327628 which were first used for the 1973 model year but became SERVICE for 68-72. Your lower hinges are likely GM #3977701 and 3977702 which were first used for the 1970 model year and became SERVICE for 68-69.
Given the history of these hinges, I am not, at all, surprised that the original hinges on your car apparently needed some "factory modification" to fit properly, especially if your car is an early 1968. By the same token, I'm not surprised that the SERVICE hinges also require some modification to work. I've never personally run into this, but given the history, I'm not surprised.
The original hinges were very thin and any swing on the door would chip plugs out of the door. How many 68-69s have you seen with these two chunks out of the doors? Later hinges have some meat in that area, but they will not fit the 68 door without cutting out a relief in the door.
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