I'm working on it!
That is, I received the inner and outer skins from Magic Metals and I am stripping the needed parts off the old door to make a new door. I am finding the rivets to be either 1/8" (skin attachment) or 3/16 (structural or lock). The rivets in the upper corners that hold the support strut are steel. The rest are aluminum. I intend to use aluminum rivets for all points.
Step 1 - remove the inside cover over the lock mechanisms.
Step 2 - remove the arms from the lock mechanism that go out to the latch mechanism.
Step 3 - drill out the rivets for the latch mechanism and remove the latch and base plate.
Step 4 - drill out the rivets that hold on the inner skin and remove the inner skin.
Step 5 - remove the 7/16" nut in the center of the lock mechanism and remove the clamp that holds on the lock, the lock, and the full width support piece. I had to remove the brass arms on the back of the lock to get the lock through the hole. Note that there are springs on each piece. Take a photo so you can position them correctly when you put reassemble the door.
Step 6 - drill out the rivets and remove the top bar (hinge point), the strut attachments, and the bottom bar (note my bottom bar is bent :( ).
Step 7 - the piece of Styrofoam supports the thin inner skin when the door is assembled. It is 1" thick and is glued to the outer skin. You can salvage the Styrofoam by gently separating it from the outer skin with a putty knife. I had a disposable ice cooler that I used for new foam.
Step 8 - clean all parts.
Step 9 - attach top bar to outer skin. Slide in the strut attachments (they will not be riveted until you do the outer skin).
Step 10 - Install support piece and lock. The support piece only goes in one way - the tabs fit into slots cut into the outer rails.
Step 11 - Install the bottom bar (I don't have mine yet - ordered yesterday). I ordered the bar from Magic Metals and it costs $67 delivered. I'm wishing now that I tried to straighten the old bar.
Step 12 - install the Styrofoam. I'm using RTV because it is what I have on hand.
Step 13 - Lay the inner skin over the assembly. Put rivets in all the holes to insure they will fit. Attach the inner skin using your rivet gun except for the latch mechanisms.
Step 14 - attach the latches and latch arms.
Step 15 - attach the lock/latch cover.
Go watch TV. You are the MAN.