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I've reset the hinges now - made sure there was load in them before screwing in.
(This also meant removing a bunch of 75mm screws and nails)
Also, using M12 x 130 coach bolts pulls things together quire nicely.
I would have needed to cut 90mm deep along the full length of the door - my saw is too small for that, unfortunately.
I put the hinges where they can screw into the noggins. I've 2 more that I may put top & bottom.
NotThamesWater
You have a track saw? Or even your circular saw guide you made. I found it much easier to trim to shape that way than with a planer.
The settling might be because you have the hinges quite close together. Any reason you didn't put them nearer to the top and bottom?