it appears that my problem is a delamination, I think the plywood was glued to the foam creating a structure that was solid, once it failed there was just foam, plywood, and fiberglass. I bet I haven't used my door more than 20 times, I thought I was the only one with the problem, but it appears to be more widespread than I first thought. I too bought the extended warranty, and haven't thought of using it, in fact, I didn't think there was a snowballs chance they would cover it. Maybe I'll try them if all else fails.