Soft door
My 09 403 did the same thing. By the time I noticed it the only thing holding the door together at the bottom was the fiberglass sheet outer panel.
On my rig, Keystone had neglected to seal the lower Aluminum U frame so water got in and rotted the board. Fortunately the aluminum honeycomb extend to the bottom of the door just above the wood base so I was able to make the door "sound" again by extending the hinge straps up to solid door.
I cleaned and re sealed the bottom U channel and then used aluminum plates 12 X 4 X 1/4 to sandwich the solid part of the door to the hinges.
From the inside out there is a 1/4" plate on the inside of the door. Then the door, then a 1/8" plate to act as a filler plate so that the outer 1/4" plate that overlays the hinge , can lay flat against the door. I bolted the bottoms of the plates thru the hinge holes , thru the door , thru the inside plate, Thus sandwiching the door between the plates. I also thru bolted the plates thru them selves and the door on the upper part of the plates.
I used 3/8" bolts and lots of silicone sealant.
Door is rock solid!!
Hope this and the pic help
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2009 Fuzion 403
2005 Ram 3500 Dually
Bully Dog, Banks, K&N
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