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Good luck but I doubt if you can fabricate a door as light and stiff as the original steel door.particularly if you are looking for smooth.
I see you used spray foam to fill in. Companies like Aircraft spruce and Wicks sell a two part foam that works very well and is much stiffer and cheaper than the spray foam at the box store.
Your door would be best left a base for a more aero structure. Just my opinion.
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