New (aftermarket remake) outer door
window rubber is 1/3 of the cost of an original.
I'll try to explain, how to install a new and weather-stripping part on the door of your 928. This will eliminate the gap between the side-window, and the aluminum outside, and finally it will stop protect the windows from scratches....!!
First take off all the door paneling including the thin plastic foil and the rubber part inside the door.
The window is held in place by two felt guides, loosen these bolts, press the guides down and pull them out.
Following that, you can work through a hole in the front and towards the rubber part outside, move it up a little and be careful taking it out and off the door.
After that you can try to install the new weather-stripping part, but if you do not have enough room between the outside door and the window to install the fixture with a finger, I’ll recommend to take out the complete window.
Take a good look at the ends of the original weather-stripping and take the new in your hands.
First cut off a small part about 30 degrees (like in the picture shown below) and hold it in a way that the longest point is facing downward.
Then cut off below the approximate 45 degree point of the edge. Use picture 35 below as a reference.
It should look like the sharp edge of a chisel now.
Grind of a bit of this 45 degrees point, smoothen it a little, create a little opening, be aware of the end, it will point al little upwards later on (refer to the original weather-stripping).
After that make three cuts at the following distances: From the end 15, 30 and
45 mm. Finally one more cut a bit more than half way through, the big part in
the middle is also done now.
Be careful not to cut the upper section of the weather-stripping, make sure that
you keep it out of the way with your hand.
Repeat the same procedure for the other side.
When you’re done cut through weather-stripping in the middle you will have two parts now one for the left and the other one for the right door.
This will give you the possibility to create one new end in case the first attempt is not good.
There is no loose section of the rubber part and the part is a little bit too long this will give you the option of a re-attempt (but be careful the amount of material is limited).
Do not use Teflon or Vaseline in an attempt for a smoother assembly. The weather-stripping will clip in the fasteners better without pre-treatment.
Check that the lower inside part of the weather-stripping (flap) is not “glued” together it might happen during the fabrication process. Separate the part carefully if necessary.
Begin as far as possible at the edge above the door lock pin, press the rubber part in. First the upper part, hold it and then with the help of the other hand press it in between the door lock and the window. From inside the door work the lower lip around the rail. Press the rubber a bit toward the edge and continue to install more of the material the same way as before. It should rest against the original material which comes in from above.
After this you have to fasten the other side, start at the front. Measure the length from the beginning and cut it long enough to be tension free later on. I recommend 2 mm extra material, this will compensate for any possible material shrinking in the future.
It might be necessary to cut out a little portion (reference photo 36) to make sure that everything works just fine. When I installed the second set in my second car, I noticed that this is not always necessary. Reminder: Press in the upper part (flap) in the split first and then the lower part (flap).
After that, you’ll have to fasten the upper part first and then the lower flap over the total length of the door.
This all can be done without taking the window out (you might try the installation with the help of a screwdriver).
For the lower part of the “V” inside the lower “flap”: Press down the rubber a bit and with another tool (or finger) work the lower fastening part of the “flap” around the rail.
Sometimes this is really difficult! Be very careful with pressure when using a screwdriver. The rubber might “resist” against installation and might not “settle in” properly.
If the upper “flap” can’t be fastened very well, you might help it by using a little bit of contact-glue in the split.
It’s a little time consuming, but the result is fine and justifies the work. Plus you’ll have the piece of mind that your window will remain scratch free for many years to come
Here are the pictures: