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Old 05-07-2008, 09:22 AM   #2 (permalink)
roverandom
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Join Date: Apr 2007
Location: Alberta,Canada.
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Roll the window down and carefully push he window frame (with the door open) inwards toward the body a tiny amount. Try the door fit. If it still has a poor fit, try it again. Continue as needed. If you do this by small amounts each time eventually you you find a spot that reduces the the wind noise to a acceptable level without binding up the door or adjusting the the entire door out of position.

If you don't fancy bending the door and, as you say the weather strip is in good condition you could try building the weather strip thickness up with foam, this does not work as well but it should help (you can get a roll of tube foam from the hardware store). Insert the foam into the weather stripping in the area of wind noise. You may have to shave the foam down for 'perfect fit' and it is tricky to get it to lay correctly but if you keep at it the foam will help.

hope this helps.
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