A DC9-30 MAIN ENTRANCE DOOR WAS IMPROPERLY REPAIRED CAUSING DIFFICULTY OPENING THE DOOR FROM THE INSIDE.

Narrative

DURING A ROUTINE INSPECTION; A SMALL CRACK WAS FOUND IN THE OUTER SKIN OF THIS DC9'S MAIN ENTRY DOOR. THE CRACK RADIATED FROM THE UPPER AFT CORNER OF THE OUTER DOOR HANDLE CUTOUT AND EXTENDED FOR ABOUT 1 INCH. A TEMPORARY PATCH WAS INSTALLED OVER THE DAMAGED AREA IN ACCORDANCE WITH THE DC9 STRUCTURAL REPAIR MANUAL UTILIZING STANDARD AND APPROVED SHEET METAL PRACTICES. AN OPERATIONAL CHK OF THE DOOR WAS ACCOMPLISHED PRIOR TO THE ACFT BEING RETURNED TO SVC. A PROB WAS RPTED WHEN THE ACFT ARRIVED AT ITS FIRST DEST WHEN THE CREW HAD TROUBLE OPENING THE MAIN ENTRY DOOR FROM THE INSIDE. THE FLT WAS DELAYED FOR ABOUT 1 HR AS A THIRD PARTY MECH (NO COMPANY MECH AT STATION) WAS CALLED IN TO FIX THE PROB. HIS SIGNOFF STATED THAT HE RESHAPED THE PATCH THAT WAS JUST INSTALLED. I CANNOT SEE HOW THE REPAIR PATCH WE INSTALLED IN ANY WAY OBSTRUCTED THE DOOR'S OPERATING MECHANISM. AS PREVIOUSLY STATED; THE DOOR WAS OPENED AND CLOSED A NUMBER OF TIMES WITHOUT A PROB DURING AN OPERATIONAL CHK PRIOR TO THE ACFT'S RELEASE.