What was found
TAKEOFF FROM BDL RUNWAY HEADING TO 4000 FEET. ON CLIMB OUT BECAME AWARE OF LOUD NOISE FROM BEHIND FLIGHT DECK. WAS INFORMED BY MECHANIC THAT L1 WAS LEAKING AIR. AT THIS TIME NOTICE CABIN WAS NOT PRESSURISING. ASKED AND WAS CLEARED BY DEPARTURE TO MAINTAIN 4000 FEET. ALL DOOR LIGHTS WERE EXTINGUISHED HOWEVER IT WAS CLEAR WE HAD A DOOR LEAK AT L1. RAN THE ENTRY DOOR QRH CHECKLIST, AND ELECTED TO RETURN TO BDL FOR A PRECAUTIONARY LANDING. GIVEN CLEARANCE FOR ILS 24 APPROACH AND LANDING. UPON POST FLIGHT IT WAS DISCOVERED THAT THE LOWER DOOR FLAP WAS NOT IN THE SEATED POSITION EVEN THOUGH THE INTERIOR DOOR LEVER WAS IN THE CLOSED POSITION AND THE CORSPONDING DOOR LIGHT WAS EXTINGUISHED. IT WAS FURTHER DISCOVERED THAT A BENT PORTION OF THE ULD IN THE NUMBER ONE POSITION HAD HIT THE SMOKE BARRIER DOOR AND CAUSED IT TO HIT THE L1 DOOR KNOCKING TO OUT OF ALIGNMENT. NONE OF THIS COULD SEEN BEFORE TAKEOFF DUE TO THE INTERIOR L1 DOOR PANEL COVERING THE AFFECTED AREA. MX AND DISPATCH WERE NOTIFIED. DISCREPANCY WAS NOTED IN THE A/C LOG. THE ULD WAS MOVED TO P2, THE MECHANIC RE ADJUSTED L1 DOOR, NEW WEIGHT AND BALANCE AND RELEASE WERE ISSUED. FLIGHT RESUMED 1:30 LATE.