Finally got the passenger door back together this past weekend. What was that.... like 3 months
It's nice and solid now though... really has some heft to it and closes with a dead thud.
I will have to replace the panel trim clips though as I think they wore out from so many test fits. Found the best price on https://www.clipsandfasteners.com/To...0_p/a21795.htm. Only ~$15 shipped for bag of 25 clips... enough for 2.5 doors worth.
Few more photos
Sail panel fit too loosely for my tastes and figured it may be a rattle generator. So I lined it with some leftover 5lb weight carpet padding to decouple.
Removed the window seal from the top of the trim panel. This allowed for much easier door panel installation. While at it I decided to add some CCF to the clips that hold it on the door panel to firm it up and prevent possible rattles.
CLD to the flimsey parts of the door trim panel:
CCF decoupled the map/cupholder pocket:
Used scrap pieces of CCF and some OCF on any surface on the back of the trim panel that came in contact with the MLV barrier. Also put a block of carpet padding in the rear to reinforce the thin plastic section (previously where the foam spacer block resided).
CCF wrapped the open/lock cables to decouple & prevent them from smacking around in there