Hi Shaun,
Parts required.
Window seals from Vintage Supplies. As per original write up.
Alloy strip from B&Q. 1mtr x 25mm x 1.5mm.
Bonding glue of your choice. I used Araldite.
The following is assuming the door is stripped down and the window and seal are removed.
The first difficult, bit the alloy needs to be bent slightly over its entire length, to suit the bend of the door lip. The the rear of the strip needs to be bent more and to a lesser degree bend the front end of the strip. This can be difficult, It all depends on how much of a practical person you are. It as to be the same shape as the door lip.
Bend it, probably is not the write way to describe the action, it is more like massaging the alloy. First heat up the alloy, not to much, Place it in a vice, flat end down and pull on the alloy, if you feel it start to kink stop, flatten out the kink and bend again. You will slowly see a bend start to appear. Check the bend with old seal and the door lip.
The seal will also need to be bent to the same shape as the door lip, but with a slight amount of heat, this is not difficult. This can be done just using your hands.
When the desired shape is achieved, on both seal and alloy and you will probably need two people for this. Hold the alloy under the door lip and fit the rubber as it should look when it is fitted, remember rubber on top of alloy. Then get someone to mark how far it comes down the alloy strip. This will show you where to bond the rubber to the alloy and will give you the gap you need for the door lip.
Bond rubber to alloy.Cut off any bits you need to so that it is the same shape as the original.
When the strip is bonded mark where the holes will go. I put a mark vertical from each hole down the door so that when I held the strip in place I could see where the holes should go. Drill holes, elongate each hole to give more adjustment.
Fit strip to door. I put one washer behind the alloy strip at the front to space it closer to the window.
Job done.
I am in the process of doing the other door, so when I have made up the other strip I will post a photo of the strip. The benefit of this method is the rubber is supported along its entire length and being alloy will not rust.
Message to mods. If this is in the wrong place do with it as you wish.
Ade