Having read the "independant" vehicle inspection report, I
would consider the vehicle unacceptable since the structural
damage was not properly repaired nor, were some of the welds
correctly done or proper refinishing completed.  These are
serious problems well beyond the door which I find to be
acceptable on a leased vehicle.  If that report is accurate,
I would do everything in my power to make the dealership eat
the sucker ASAP.  I would not spend this many years of my
life picketing and getting even - it's too expensive.  If
the insurance company can't/won't step in to correct the
problem, just sue the bastards! The problem with a leased
vehicle is the potential to have the vehicle appraised well
below what it would have been worth in the absence of prior
damage or improper repair at trade time.  To me, improper
repair is less acceptable than a vehicle that has been
damaged and properly repaired.  I have no problem with a
good used door properly repaired.  Many insurance companies
will not use new parts beyond a certain age or mileage
unless the new parts are comparably priced.  It would appear
that the adjuster built in a few freebies to make sure the
vehicle was properly repaired eliminating any excuses for
the vehicle to be slipshod reapired.