I drove a few vans before I found my Mythic Church Van. Most had damage at the forward edge of the doors, where the action of over-opening the doors has separated what looks like a simple stamping by Ford.

You can best see the issue by opening the door, pushing it forward to its limit, then nudge it forward a little more while observing that edge from the inside.

I've seen people try to weld it up...messy. The welds broke and caused rust.

My driver door is starting to move a little bit there. Has anybody found a good solution to avoid the problem? Some kind of adhesive? A crimped U-channel of SS from the outside?

Ideas...

 

swap out the door

 

Yeah. But while it's off, why not weld a nice little bead with thin SS wire, then paint it? The front side of the door resting in water to keep the paint from burning.

 

Check the hinge pins