He lives in the USA....
I think his dealer has been very accomodating so far. Just a rash of bad luck with both cars. I think he should have kept the first one. A misaligned door is not nearly as bad as a cracked engine block at 350 miles.
I would say, try again, have the dealer order a third replacement... And if that doesn't work, call it a day with MINI ownership.
Send a letter to Jim McDowell.... He is the president of MINIUSA.