The right way to seal your doors

I wish I had read the posts on the 2002 FAQ first...  I tried to use a single sheet of plastic, and attach it to the inside of the door with caulk - underwhelming results to say the least.  I followed the FAQ suggestions, more or less, but I really like using individual pieces of plastic to cover all of the holes since you can go slowly and focus on one thing at a time.  I think the individual pieces are also probably easier to keep from sticking where they're not supposed to stick than if you're working with a whole-door sized sheet of plastic.  Also, I went with a 4 mil thick plastic since I think it'll last longer.

First, remove old rust and make sure it won't come back!  The brown is a rust-stop primer, not rust.  :) Oh, right, after you scrape off all of the caulk from the failed attempt to recreate the factory sealing.  Grrrr.

Never mind what it says about spraying it onto both surfaces - what a huge mess.  I found it very easy to spray it onto a brush and spread it onto the metal.  I waited less than a minute before putting on the plastic.  Getting the plastic on while the glue is still a little wet will let you push it into the contours before it sticks so much that you can't move it. It doesn't like paint, so be careful about dripping.

Finally, nice results!  I'll trim off the excess plastic after the glue is really dry (overnight, probably).  The red tint is from dissolving a bit of the paint.  I tested it on another spot and saw that it doesn't go all the way to the metal.  Either way is probably OK since the glue will seal it when it dries.

Here's what it looks like when you spray it on to both surfaces.  The process is really tricky since the glue bonds immediately when you touch the plastic to the door - no second chances.  I also think working the plastic into the curves while the glue is a bit wet might also give a better seal - more conforming to the nooks and crannies.  That said, these pieces of plastic are NOT coming off easily and they've stood up to the water I sprayed onto the window (and therefore into the door).