[dsraven]

That sucks about the door opening edge. Are you using a flap disc? I find them great for rough work but they flex a bunch so around an edge or a body line you gotta be real careful. Same when grinding the high spots off a weld, it's easy to also bring the surrounding sheet metal and then you have a thin spot. They heat the metal up around the weld you are grinding down and it oil cans a bit so the surrounding sheet metal is easy to find itself high and get flap disced a bit.