Continued working on the emergency door, stripping off all the old aluminium cladding.  It now fits, more or less and should be ok when the locking clamp is refitted which will pull in the bottom.  The natural tendency for it to spring outwards is probably intentional so as to aid its opening.   I found that many of the  the joints on the door frame had loosened, so I reinforced these either by adding a new screw or drilling and gluing in a 6mm x 30mm dowel.   I ordered the aluminium and the some 5mm dowels for the rebuild.  Whilst waiting for these to arrive I created the template for the emergency door window frame and started to build it.  I got as far as welding the first corner flange onto the base for the rubber by the end of work this week.