Thanks for asking! I found some old Forum links for fixing door warps, and followed the directions in them, so far. See photos. The major bend in the doorframe (in the wrong direction - out) starts where the deadbolt was - you can see the steel reinforcement bar for the locks in the side edge of the doorframe. Pretty strong panel, but it is also is keeping the door from bending back. It has special rivets holding it in that I have yet to remove, as I am researching how to replace them first, before I drill them out.
After struggling with Hinge Pins that would not budge, I used a Dremmel and cut through the hinge pins at the openings above and below the door hinge pieces. Door came out nicely, and I will deal with vestiges of the hinge pins in the Trailer half of the hinges later.
I am removing the aluminum skins (inner skins removed in Photo), Outer skins next; and will then screw the door frame onto a "door form" that I will make from 2"x6" wood, after scribing the form on the door opening on the trailer. The outer skins are adhered to the frame, with a lot of adhesive tape and caulk, so I have to fabricate a tool to cut all that adhesive out between the outer skin and the frame. I am making that tool by sharpening a drywall putty knife. These doors were made to be pretty solid.
When I get the outer skins off, I will then screw the frame to the wood form using all the rivet holes around the perimeter. I may have to heat and hammer the frame some to get it to fit the wood form well. If the frame will not bend enough to mostly fit the form, the door will leak, so I am determined to make this work.
Because the replacement door is so expensive, I am almost ready to leave the door unlocked for future thieves, and just empty the AirStream for storage periods.
It would be better if the thieves broke a window, instead. That only costs $350, and would take about 3 hours to replace. This door repair is going to run into about 15 hours, with no guarantee of a good fit!!! Any suggestions? Thanks in advance!! John F
They used a crowbar to lever the bottom of the door, on the lock side. It broke the bar on the deadbolt, and warped the door out about 8-inches. The local AS dealer has quoted me a new door at $2,500, with labor at $1,500, for a total of $4,000 with tax!! This feels like an insurance scam to me!
JohnF______
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