I, too, have a big baby.
Mine leaks (Problem: I learned how to cut the door using a sawz-all and failed, requiring a door made from a non-matching barrel).
I am trying to use RTV Caulk on the outside of the door to close the gap. My first two attempts minimized the leak, but i want it as close to zero as possible.
I used the scrap metal from the damper holes to create my plates. It worked with some success. If it hadn't, my next move will be to use the jacked up door to create the plates.
Dbl Bbl Smoker, UDS, ECB, Char-Broil gas grill & charcoal grills, SJ - Certified Moink Baller