Narrative:

First officer and I had taxied aircraft, an ATR72, from the hangar to the terminal. A new aircraft logbook was in the aircraft so I could not read aircraft maintenance history. We boarded 64 passenger and taxied out. First officer could not program adu properly. We returned to the gate and got it fixed. We left gate again and all was normal. Shortly after lift-off, +/-1500 ft MSL, the #1 flight attendant called and reported a very loud noise from the main cabin door. She also could see daylight through the door seal. I told my first officer to level off and reduce speed to 180 KIAS. Flight attendant #1 had a very difficult time hearing me and I questioned her about the door. She told me the top of the door was flexing, not the seal, but the door itself. We decided to return to dfw. No emergency was declared. Landed uneventful. Maintenance informed me, at the gate, that this aircraft was returned to service today, with a door of another ATR aircraft. There was no checklist for this incident in the QRH.

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Original NASA ASRS Text

Title: AN ATR72 IMMEDIATELY AFTER TKOF AND INITIAL CLB EXPERIENCED THE MAIN CABIN DOOR TOP SURFACE FLEXING CAUSING LOUD SQUEAL.

Narrative: FO AND I HAD TAXIED ACFT, AN ATR72, FROM THE HANGAR TO THE TERMINAL. A NEW ACFT LOGBOOK WAS IN THE ACFT SO I COULD NOT READ ACFT MAINT HISTORY. WE BOARDED 64 PAX AND TAXIED OUT. FO COULD NOT PROGRAM ADU PROPERLY. WE RETURNED TO THE GATE AND GOT IT FIXED. WE LEFT GATE AGAIN AND ALL WAS NORMAL. SHORTLY AFTER LIFT-OFF, +/-1500 FT MSL, THE #1 FLT ATTENDANT CALLED AND RPTED A VERY LOUD NOISE FROM THE MAIN CABIN DOOR. SHE ALSO COULD SEE DAYLIGHT THROUGH THE DOOR SEAL. I TOLD MY FO TO LEVEL OFF AND REDUCE SPD TO 180 KIAS. FLT ATTENDANT #1 HAD A VERY DIFFICULT TIME HEARING ME AND I QUESTIONED HER ABOUT THE DOOR. SHE TOLD ME THE TOP OF THE DOOR WAS FLEXING, NOT THE SEAL, BUT THE DOOR ITSELF. WE DECIDED TO RETURN TO DFW. NO EMER WAS DECLARED. LANDED UNEVENTFUL. MAINT INFORMED ME, AT THE GATE, THAT THIS ACFT WAS RETURNED TO SVC TODAY, WITH A DOOR OF ANOTHER ATR ACFT. THERE WAS NO CHKLIST FOR THIS INCIDENT IN THE QRH.

Data retrieved from NASA's ASRS site as of July 2007 and automatically converted to unabbreviated mixed upper/lowercase text. This report is for informational purposes with no guarantee of accuracy. See NASA's ASRS site for official report.