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Re: Gaps and Wind Noise
A couple comments:
a) Be reminded that these things were noisy when new. Wind noise, particularly in the A pillar area, was a "hardy perennial". Secondary door seals would come (when customers would complain) and go (when management was looking for cost reduction opportunities) over the various model years and trim levels.
b) As a diagnostic technique - you can tape up the gaps and joints on the outside of the door and remove small sections to help you pinpoint where the noise/air is coming from. Tape up all the way around with masking tape or duct tape and then remove a section from the A pillar to see what happens; tape that back up and remove the section from the window belt molding/seal and see what happens, etc.
c) Panel fitment can also be cheated to help. "Shingle" the rear edge of the fender so it is slightly outboard of the leading edge of the door. Tuck the top of the door (in the A pillar area) so that it is slightly inboard of the A pillar portion of the cab. These will help with airflow over the vehicle but will not be obvious to the casual observer.
d) Even with everything perfect and new - you may still have some wind noise from the vent window area.
K
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