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Okay guys, Thanks for all the replies, I decided to bite the bullet and dump the door its just not cost effective. As they say in the movies "thats a wrap" Thanks again.

Thanks for the offer awbcm but I'm looking for an easy fix, and I'm really not confident about taking out the door frame. The door frame already looks pretty rubbish anyway. Deluks what do you mean by "Were you to fix through a widened bit you'd need longer screws too" Maybe it is better...

For whatever reason (either I gave the wrong code or I lost my mind when I measured), the new external door that I ordered is shy some 40mm wide and 20mm high of the door frame. :oops: The question I have is ... Can I make the door frame smaller to fit the door? The door is 762x1981mm...