Ok, so I decided to give something else a try. I ordered some self adhesive velvet sheets and 1mm thick felt. If this all works out and anyone wants to do the same, I can link to exactly what I bought off Amazon for this.
After taking the door apart again I did notice that the foam washers I made really did get squashed down, so I created some new ones from the 1mm thick felt that I got, I have a feeling these will hold up much better and not crush like the foam. At the same time I decided to replace the paper ones as well with the felt. Getting those out was easy, but putting the felt back in was more of a challenge since they are much thicker. With a little patience and creativity those are all replaced.
View attachment 12975
Now here is where the velvet comes in. I am cutting strips to line all of the surfaces that come into contact with the door card and could potentially rub along the vinyl.
View attachment 12976
This is pretty much where I am trying to avoid any contact on the door card
View attachment 12977
Lastly, since I had it apart again, I decided to put some of the velvet along the tabs that lock the top piece onto the door itself. There are 9 of these areas that I did. I had only started when I took the photo.
View attachment 12978
Once this is all back together and I have some time with it I'll update this to let everyone know if it has really solved anything. Now it could take a little time to report back any success/failure since I am still having issues after the engine replacement and it's going back to the dealer Monday morning for that again.
After taking the door apart again I did notice that the foam washers I made really did get squashed down, so I created some new ones from the 1mm thick felt that I got, I have a feeling these will hold up much better and not crush like the foam. At the same time I decided to replace the paper ones as well with the felt. Getting those out was easy, but putting the felt back in was more of a challenge since they are much thicker. With a little patience and creativity those are all replaced.
View attachment 12975
Now here is where the velvet comes in. I am cutting strips to line all of the surfaces that come into contact with the door card and could potentially rub along the vinyl.
View attachment 12976
This is pretty much where I am trying to avoid any contact on the door card
View attachment 12977
Lastly, since I had it apart again, I decided to put some of the velvet along the tabs that lock the top piece onto the door itself. There are 9 of these areas that I did. I had only started when I took the photo.
View attachment 12978
Once this is all back together and I have some time with it I'll update this to let everyone know if it has really solved anything. Now it could take a little time to report back any success/failure since I am still having issues after the engine replacement and it's going back to the dealer Monday morning for that again.
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