Lord_Athlon
300+ Clurb
- Joined
- May 20, 2003
- Location
- Eau Claire, WI.
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Did you ever verify its not the windshield?
I participated in an OEM vehicle launch and they legit fixed odd noises with some BS fixes, there was some whistle caused by a hole for screwdriver access on a side mirror, tiny piece of tape, whistle gone.
So... my 245 has the antenna there running along the A pillar, that could also be playing with the air and changing the noises.
I'd somewhat suggest taping the door shut from the outside, crawl in via a different door and confirm if full blocking of airflow fixes it. Then remove some of the tape, drive again.
If you think door alignment is a problem (it totally can be) then watch some videos on door fitting (like https://www.youtube.com/watch?v=6hEx-wgrdAw). The connections for hinge mounts are not precise shoulder bolts, they are fat clearance and you can wiggle alignment on them with either a plastic chisel or pulling, pushing, being violent with the door. Doing adjustment to the striker may be all you need for the extra closing squish needed to end the noise.
It's also possible that the door hinge is just too worn out. Is there any slop if you try to lift the door up while it's partially open? Not a hard fix, just have to use a floor jack under the door, then remove the kick panel, move the fuse block out of the way, and replace the hinge. I need to do that on my 242.
No 87+ wind-lace mouldings across the top of the doors?
Put masking tape around the perimeter of the driver door or at least some sections, get in from the pass side and drive- if the noise is not gone then it's not the door. May be the mirror. I added inner seal to my '76 and it made the big difference.
The window frames can bend slightly with age, and they don't preload the seals as much.
You can easily yank the window frame in a few mm and preload the seals and stop the leaks. This also keeps the lower section of the doors and fenders aligned. Just pretend you're working on the Yugo assembly line and tasked with hanging the doors.
The 242s are terrible about the window frame deflecting over time (and cracking the welds).
I think you are chasing your tail. 240s are known for a lot of wind noise. I just drove a 240 wagon I have the other day and that is what immediately came to my attention. How much wind noise it generates compared to my more modern cars.