The self destruct tab should not be an issue for you. Safe to leave alone.
I can't tell which side the protrusion is in your photo. Maybe because too close. If you copied me it's a non issue. The close tolerance is on the other side.
This is the tight side.
This is the non tight side.
I think you got it right and made it literally stronger than new.
Put some lubrication on the gear.
I think a primary cause of breakage is attempting to open a locked door.
I haven't used e53 in a while but I seem to recall a locked door the DLA locks the motion of the outer door handle rather than the century old tried and true method of "dry fire" that just detaches the handle and does nothing.
If I remember correctly, teach your family & friends to wait until you unlock before pulling the handle. (It literally won't matter on the fixed one that is nearly unbreakable).
(Out of ≈ 20 repairs over helped on only 1 broke somewhere besides that hinge break).
Of the 8 doors on our e53s I repaired 5 I think of the DHC.
I also rebuilt 3-4 of the DLA when the motors wore out saving over $200@.