Thanks for offering to take a look BurrMan, Here is the exported 3DM file. On the photo you will see the angular "seams", for want of a better word. Although these areas are sharp compared to most other cars, these are still like rolled seams. Feel free to play with it and see what you can come up with, as I am positive the error is with my modelling technique and not MoI's toolset. There are more fancy commands in Rhino, but they are still using the basic infrastructure that MoI has, more like refined scripts.

The area round where the door will fit needs to have more volume, as said in previous posts, I normally offset an edge and then loft them together to get surface which can then be Filleted.

Hope this all makes sense, it would be cool to learn how to do this part of modelling vehicles as it's always where i goof it up.

Martin