After researching more on the forum, I have come to the conclusion that a "forensic action" is required for the door. One of the threads I saw had photos of the door cut open. The fiberboard "guts" of the door had been exposed to water just as ours has been. It was NASTY. I'm pretty sure that ours is toast. And it's HEAVY....
Thinking that it was waterlogged, I drilled several holes across the bottom. Nothing came out, but as you said, that fiberboard has probably soaked it all up. It's also probably growing stuff in there, too. Yuck.
I could order a new door from Scamp
, but you're right -- the shipping would be killer. And I know that our pod is not quite "square." So a new door may have the same issues as we have now.
I know we have issues with the door frame... The POs, when they installed the new floor, they did so without keeping the door frame square -- so the door opening is about 3/8" wider at the bottom than the top. So, right now the plan is to brace the door frame using wood "struts" which will become part of the cabinets, and then, once that's secure and solid, we'll "recurve" the door.
In the mean time, we'll schedule the door for surgery to get that nastiness out of there. We'll then see about putting in struts inside and fill in the voids with the insulating foam before sealing it back up.
And as for the D foam, would that be better than the new stuff Scamp has on their site?
Thanks for the advice!!