The problem was the plastic lugs that are bonded to the glass have little raised bits to keep things tight and rattle free but these wear out. I know others have done a solution to this that requires removal of the window, heating the lugs while clamping them thus closing the gap, but I really didn't want to take the window out so came up with my own solution.
Start off by having a good look down into the door at the lugs to see how much of a gap have opened up in them. I decided some mini trunking, that'll be the £4.49, had the correct thickness, the stuff I got was 10x16mm, although the bit you'll eventually use is about 1mm thick plus the adhesive strip that was already attached. Pull the two parts of the trunking apart as you only need the bit with the sticky on it.
Wont go through getting the door panels off as it's been covered. To remove the rear rail just undo screw at the top of the rail, then unscrew the two little, erm, screws that hold the lower adjuster. The rail will now be free, I then undid the adjuster (anticlockwise) to remove it from the rail because I couldn't pull the rail out with it attached. If you can get it out without removing the adjuster you'll save yourself the frustrating and for me time consuming job of lining it up and screwing it in, while inside the door.
First off cut the trunking down to size, handily the adhesive strip was the correct width so was a good guide.
I then drilled a hole right at the bottom of the rail to bolt the trunking as a fail-safe but not sure if it's strictly necessary. After cleaning the rail with white spirit I stuck the trunking to the rail with the attached adhesive strip.
Then all you have to do is put the rail back, as I said before the worse thing was the bloody adjuster but apart from that just make sure rail sits in the window lugs and you've got full movement. Also it makes sense to adjust the window while all the door panels are off.
Think that's everything Winding has ever so slightly more resistance but nothing to be worried about, but this does mean no more bloody rattling
Edited by VXT'ED, 20 July 2011 - 06:52 PM.