The hinge corner on this door was BAD. Someone before me used C channel, steel rod, and some nuts to repair it, which wasnt too bad considering it was basically a quick fix, but it wasnt good enough for me.
I cut that garbage out, and I'm welding in some slightly better garbage
My donor was much better, but still broken, so I first made a thick, strong backing plate to hide behind the cracked sheet metal. After I drilled and bolted it in, I welded it to the back of the hinge support in multiple places (not pictured) From the outside, it will appear to be in dire need of repair, but magically strong somehow!