I finally pulled the door card off the 944 today to deal with a very loud new rattle, along with some smaller ones that have been there for way too long. The big new rattle was just the screw that holds the window rail secure, as I suspected. I saturated it in green loctite and tightened that one up in no time. Also secured a few harness cables, but it took half the afternoon to find the last vibration.
It turned out to be a strip of composite panel glued to the inside of the door (see video below). It's listed on the sound insulation page in PET but call 'insulation' even though almost everything else on the page is called "sound absorber" -- so can't really say what it might be insulating from what. What I do know is that the hinge end of the panel had come free and was resting against the window rail, and at just the right frequency it would rattle and hum. I glued it back with 3M weather-stripping glue, and it seems secure, but time will tell. Duct tape might be in its future... Just thought I'd share since it was such a weird rattle source...
944 Door Rattle -- new one
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Tom
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Tom
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Maybe I was slow on the uptake, but I overlooked it for an hour or more -- primarily because it just seems like a part of the door panel. Hiding in plain sight...