Once paint was stripped, i placed a straight edge across the door face to see how badly damaged and the extent of repairs needed. Though you cant see it from the photos, the door had both low and high spots, which couldnt be reached from the back side due to the door frame/webbing.
I also noticed surface rust on the underside, so i decided to drill out the spot welds and separate the webbing from the door skin and address the rust issue...

Bit extreme, but needed to be done. Its either do this, or throw away and replace.