I had to do something and this is what I came up with to make some much needed clearance. By using my Dremel and a sanding drum, I removed some paint and some steel too. I figured that I could always use a brush and do some touch-up.

After trying the door like you see below, I didn't have enough clearance because the door was still having a hard time shutting all the way. That meant I kept using my Dremel until I had the door working like I wanted. However, I didn't take a picture of it because I got into high gear and just wanted to finish it. I ended up sanding along the top and bottom of the door (about half way down) and I made it wider along the back which did the trick. 
 

Interior

The interior of a safe can be anything you want, depending on what you're going to keep inside. Well that's the question, I'm not sure what my grandson is going to put in it. With this in mind, I'll just lined all six surfaces inside and if he wants something else in the future, I'll change it or add to it.

Doing this kind of interior isn't difficult but it does take time. I decided to use some wood paneling for the structure (less than 1/4" thick), cover that with 1/4" foam and then cover the foam with material. I did something similar while working on my 33 Ford awhile back. First I made a cardboard template of the size I wanted, then transferred that to the wood and then cut that out. After sanding the wood, I cut out some foam slightly larger than my wood piece.
 

I'm using some spray glue, which is the same stuff I used on my car. What you do is spray both surfaces, wait 5 to 20 minutes and then stick them together. I make sure to rub every square inch and use downward pressure while doing this to make sure it sticks well.
 

Now it's time to cover the foam with some material. And for that I'm using some thick felt. They make all different thickness' of felt and I wanted something that would last for him. If you're wondering why all odd shaped cuts, that's what it takes to make it look right for this piece.

At this point I've glued on the material, but have not applied any glue to the edges yet. This is where you do a series of cuts to fit everything before gluing. Note: if you cut to far on the notches, say to close to the wood, you'll see it on the finished side when your done, so you have to be careful with your scissors. Now that all the cutting has been done, it's time to spray some glue on the material and wood surfaces, wait a few minutes and then fold all the pieces onto the back.
 

I know this is a different piece below, but if everything goes according to plan, you should end up with a nice looking piece when you're done. The piece below will be for the top or bottom, because they're both the same size. And if you're wondering why I didn't show you the other piece from above, it's because that piece is really hard to get into the box. You have to wiggle, slide, push, move a little more, this way and then that way so it will fit. Once I had it in, I left it.
 

I know the lighting is bad but this should give you an idea what it's going to look like. I could have given Aidan an empty safe without an interior at all and saved myself a lot of work, but that's not how I do projects. Even if I dig myself a hole, I'm willing to give anything a try and go from there. I mean, what's the worst that can happen?