[Tcoat]

Originally Posted by Spuds

It almost looks like the panel is trying to bow inwards slightly and being stopped by some structure, but I can't really tell from the pictures.

Throwing some ideas out there. This is indeed weird.
Has the door had any excess weight applied to it? Maybe someone fell into it and weakened the skin enough to get it just starting to yield, so that air pressure when driving it causes it to get worse.

OR.... !!!

I think I've got it here, hear me out.

Anyone know how the door skin is kept on the frame? Is it spot welds in the middle, or is it suspended by the exterior structure? Because, if one broke or a few we're not good, the aluminum skin would be free to vibrate at speed. Aluminum has no fatigue limit, meaning that no matter how small the vibration, it will eventually yield. Yielding under load would cause expansion of the panel, thus deforming it. If there's some structural member behind that crease, it would yield around that member under aerodynamic load, and possibly pop back out when there is no load.

This can also happen if the skin were to be too thin, or defective in some other way regardless of the attachment points.

This is more or less what I was thinking when I asked if there were any weird noises or window issues. It isn't aluminum though it is ordinary sheet metal. The only aluminum component is the hood.