It sounds like you need a whole new door now.
Anyway I don't know why you guys are using an aluminum plate? The strong arms that are used are too strong for the doors. I'm thinking it would just bend and cause movement then rip off as well. I took mine in for this same reason after 3 months of owning the trailer. What my dealer told me they do is install bolts through the door and use a weaker strong arm. hmm NO, I don't want bolts through my door. So I took the trailer home and thought what I can do. What I ended up doing was taking the brackets to a welder and welding them to a 1/8" X 2" X 12" flat bar. Then I screwed it down with the same size of screws that the original bracket had, I did not predrill the door.
I tell you this because if you do get a new door it will eventually do the same thing. It's been 2 years and my door is still solid.
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