Today has been a busy day and, hopefully, a productive one as a result. The first thing to arrive was the new door seal, ordered from https://www.carbuilder.com/uk and I have to say I have absolutely no problem with their service or product so consider them recommended. After failing to cut the corners on the Princess door seals in the way I wanted to, someone suggested using a mitre saw... I don't have one of those but I do have a model making saw, which is suitable for the task and allowed me to make a nice 45 degree cut.
I'd already measured the door hole and found it needed 3.5 metres of seal for the front door, which meant having to order 4 metres which came out at about £25. Fitting is very easy, I loosened the screws on the door trims but didn't remove them because that way I can still fit the seal without having to try and re-find the screw holes. Seal went on lovely and fit really snug, I was very happy.
Then I saw the mistake I didn't know I'd made. The old seal has a fatter profile than this one so while this one fits on the door rail perfectly as it should, it doesn't get squashed to give a nice seal. This isn't a fault of the supplier, this is entirely my fault for fudging up the measurements on the old seal because I hadn't compensated for how squashed it was. This means you could see through the top corner of the door and, presumably, all the water would get in through there too. Putting the old door seal back on was not an option, since it seems intent on funneling water into the car through the damaged section of it.
My solution, since I'm out of cash until I get paid again, was to make use of the left over foam sheet I bought for the tailgate panel and make some strips of foam to take up the gap and squash the door seal down. This is such a giffer fix that I'll be off to collect my bus pass shortly since I clearly now qualify. I used the same foam to replace the bit around the door lock too so the pin doesn't rattle in the door. You can also see the new membrane I fitted here, because the new door solenoid arrived today.
Happily, the giffer fix did seal the gap and the door has that nice fresh seal resistance when you try and shut it. I'll probably leave this as is if it keeps the weather out and save up to get all four door seals replaced with new since the old ones are clearly very tired, I just need to find an edge seal that's fat enough.
The other job I did today was the door lock solenoid. The replacement isn't a direct fit, I did know this from other BXer's threads. Before getting the drill out, I tested the new solenoid to be sure it was a mechanical failure of the old unit, and not a problem with the wiring. Happily, the new solenoid works as it should. To fit, I knew from other BXer threads this wasn't going to be entirely straightforward. The first problem is that the bolt holes are in different places and the throw on the new solenoid is longer than on the old solenoid. My initial plan of using one existing hole and drilling a second one for the other bolt hole had to be changed to drilling two fresh holes to compensate for the 10mm extra throw. Once that was sorted, I then had to bend the lock rod end around 90 degrees because the new solenoid requires that. Putting the new solenoid in the vise I could at least use the original bolts to tap threads into the bolt holes in the casing so I didn't have to rummage about for replacement bolts. All done, it was fitted in the door and while it's a little noisier than the other solenoids, I'm pleased to report it works perfectly and I now, for the first time in my life, have a car where the central locking works on all the doors properly. Feels dead posh does that.
Working locks, door all sealed up, hopefully a waterproof door seal, the last thing to do was refitting all the door furniture and trying out that velvet ribbon experiment. I'm calling this a partial success. Initially the window did not like going down but after a few ups and downs, it worked as well as it used to. The door seal does still try to roll under and get stuck but nowhere near as bad as before the ribbon treatment, and the window goes up much nicer now than it did. With a bit of use, the ribbon will probably wear down a bit and might even stop rolling the tiny amount it does in that one spot, but I'll be buying some new weather stripping instead and fixing this properly, in the future. It'll do for now.
So there you go, that's today's antics up to date. Oh, and water is still getting in on the driver's side somewhere. I think I know where, it just means broggling about behind the sound deadening panel in the engine bay and getting my head in the wheelarch, and that's going to have to wait for a day when I have more time.