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A current working theory (from people more expert than me) is that Spirit Aerosystems (who builds the fuselage) does a loose install of the door for transport to Boeing, who then does a final install of the interior. Since this door is usually removed for the interior installation the theory is that it isn't and the loose install is what has ended up on otherwise flight worthy planes.
I was recently in Wichita at the airport where spirit aerosystems builds fuselages and could see a large Boeing plane that transports the fuselage inside it to Washington to be finished