Door Seals 2019: latest and greatest?

Happy to share all my observations... but you guys need to help me with hardware before I can get these installed. I was trying to do the right thing and get metric sized sheet metal screws instead of using the closest approximation which would be a number four. Alfa specifies M2.9 in the parts manual so I ordered some. However they felt loose when going in and sure enough when I measure the original screws I get .115 inches. I am not really sure if metric screw sizes changed over the years or maybe this is not technically a sheet metal screw but some other bygone standard.

Anyone find a good replacement ?

This is a guess on my part, but there appears to be a tolerance on the outside diameter of an M2.9 thread (as well as the inside diameter), with the maximum allowed diameter at 2.90mm and the minimum at 2.76mm. When you take measurement instrument accuracy into account, I'd say both the M2.9 and the Alfa screw are within tolerance. The new screw is close to the bottom end while the "Alfa" screw at the very top of the tolerance range.

https://www.trfastenings.com/products/knowledgebase/self-tapping-screws/thread-geometry

As a side note, as industry has improved its manufacturing precision, they have found money in targeting the lower end of a specification. For instance, 316L stainless steel contains 2.0 - 3.0% molybendum and 10 - 14% nickel. Steel manufacturers used to target the middle of the range, but now have the ability to get a lot closer to the bottom end of the specification and still have meet their minimum quality specs. There is obviously money to be found here for the steel manufacturer, but it caused some surprises to end users who always expected their products to withstand specific environments.

I'm not a familiar with screws, but in this particular case, looking at the minor diameter, the difference in metal between the minimum and maximum spec is 8.7% in term of material.That is a significant difference is all you do is make screws.

Thanks all. I have the drivers side test fitted and preliminarily it feels good. Bear in mind that every single part of the door system on my car has been rebuilt. The gaps are very nice without the seal but nonetheless there are lots of variables as you all know. I do have an approximately 2 inch section of extra seal when I am done with the install. I don’t believe I was stretching very hard at all as I went but I understand this is a common issue with all seals.

Can anyone confirm that this is most likely an installer not part problem? Any tips to ameliorate it?

I am also seeing that the inside rear corner of the stainless window trim is pushing the door seal out of its channel. Does the relationship of the seal to the stainless trim look wrong?

Before closing door, door closed, door open pics:



Confirming the channel is as far inboard as it can be View attachment 1606916

Pulled the inner stainless trim and the door sheet metal still nudges the seal. Anyone have a pic of how this is supposed to look?

View attachment 1606917

Believe the door sheet metal may be bent to the inside some. View attachment 1606918

Here’s what it should look like... the end of the interior SS trim should be near flush to the forward crease of the seal recess in the door.

I was excited to see this post as I just complete the weather seals on my 74 GTV and I am having the same issue on the drivers side (passenger is fine). Like you, I verified that the inner chrome strip is as far forward as possible based on the attachment point at the top of the door as well fitment with the chrome strip that it touches at the front of the door frame. I also have rebuild the hinges with new pins and bushings. What I did find was the weather strip touched at the door bottom more so at the front of the door, so I adjusted the door hinges a bit upward as well as pivoted at the top a bit outward. THis did make things a better. If you do adjust the hinges take care not to adjust them outward too far -- and simply slam the door to check fitment -- as the upper hinge can move far enough to cause the door skin to pinch with the fender near the top. While things have improved it is still not perfect (or as good as the passenger side).

One other point, did feel the ones fromI have both the Alfaholics and Classic Alfa seals. They are very similar. I did feel (qualitatively) the Classic Alfa seals were a bit more flexible -- I purchased them in 2015. I understand the version today has an embossed mark on them from Cicognani. My versions do not have this mark. I am curious how they stack up and I look forward to your updates.