When the over-extended door creases the outer cowl, it tends to twist the hinge pillar toward the front of the vehicle.
When you assemble the outer cowl, inner cowl, and inner-to-outer cowl, don't tack weld them. Use small hex head self tapping screws. Pre-drill the outer panel so that the panel stays in place while the screw drills through the metal under it.
You will find that you will need to do a lot of repositioning of panels to create the perfect hole for the door to fit in.
When you are screwing these panels in place, locate the screws where a spot weld would normally be. That way you will have a hole already in place to weld the panel into place permanently once your door fits and latches.
