Alright, I found the culprit last night for the rattly door. As soon as I pulled off the door card, a little cadmium plated bolt/washer fell out. Turns out that it fell out of my window frame, which explains the rattle when I close the door and made it sound like I had a blown speaker.

All I need to do was remove the door card, lower the window so the frame had some give, position the frame in the right spot, and put the bolt back in. No problem!

I'm wondering why it was fell out so easily though. I'll be taking my door apart sometime this summer to clean up the motors and regrease the frame rails. Might do some sound deadening in the door panel at the same time.

 

Im having this same problem, can you post a pic of the culprit?

 

I have everything back together and I'm back out on the road unfortunately. I can draw something up to kind of show what happened and what made the noise. Gimme about 30 minutes and I'll draw it up.

 

Okay, you'll have to forgive the crude drawing. This was done by memory and I don't remember the exact location or quantity of the bolts...



This is the inside of the door after the door card has been removed. What happened was the green-gold bolt inside the dashed circle fell out which left the window track free to rattle around be annoying as hell.

Here's how I fixed it.

1.) Remove all black bolts around perimeter of secondary door frame (SDF).
2.) Find and inspect the missing bolt (it was easy for me; it just fell out once I removed the door card.
3.) Plug your window switch back in temporarily and lower the window 3". This will allow a bit of movement in the window frame tracks and makes it a LOT easier to line up the loose track with the SDF.
4.) Apply a little mild threadlocker and put bolt back in, but don't over tighten.
5.) Check other cadmium plated bolts to see if they're loose. Tighten as necessary.
6.) Test window functions, then remove window switch.
7.) Reinstall SDF, reconnect all locks, lights, install door card/window switches/trim.
8.) ????
9.) Profit.

My car no longer sounds like a 1978 Nova when I close the door now.