Bob
Have you considered glueing the skin? If you are willing to use the pan brake to make the first 90 degrees of the fold, then a hammer to do most of the rest (probably with a block to make a longer working face to avoid dings), we should be able to devise tooling to uniformly close a partially folded seam. All of this is obviously trickier on the curved edge of the door, you might want to get the straight edges done first, let the glue set and then come back to the curve.
We can discuss this one day at the barn when we can look at the door, draw sketches, make mock-ups and talk with our hands.
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14-10-12, 18:54
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