Project M on 2nd Gen

Love my new Project M, but there's a bit of a problem with the door fit and dust, and they say it is 2nd gen specific, so here I am in this forum instead of the 3rd gen thread.

Anyone else having issues? The door does not fit tight to the tailgate and I've been waiting since March for some resolve.

I'd already installed foam along the bottom of the underside of the door. A second row of stick-on weatherstripping was added atop the tailgate, but it only lasted one trip.

I've been in contact with them, but it's moving slowly. I understand current situations with Covid.

I'm mostly curious if I'm the only one with this level of dust intrusion.

There's literally almost an inch gap from the tailgate to the bottom of the door.

If you have this same config, I'd love to see close up pics of how your door fits.

 

Dust is an unavoidable thing for sure.
I do not have the Project M.
I'd like a photo of how the door fits to your tail gate, if possible. The way you describe it makes me want to see.

so i've checked their website and a couple photos this forum. looks like at least three different hatch seal scenarios. No consistent fix from the get-go.
I have a AT Habitat and DUST incursion is an annoyance. I also get rain water thru the hatch.
I try DIY fixes, seems to be an on-going project.
The 2ndGen tailgate has really large channels for dust incursion. got to start with the tailgate itself. ive stuck doorseal in places such that the tailgate is now hard to close. I try to block the spaces where I can see light.
I saw a partial pic of your hatch door. looks like a curved plastic lip overlapping your tailgate. first thought is that plastic lip needs to extend laterally beyond your hatch, to cover the gap where tailgate closes. Then that plastic curved lip needs to have closed cell foam glued into it, and carved down with a sure-form rasp to closely fit against your tailgate. i used to use contact cement to glue big chunks of blue closed cell foam to fiberglass and kevlar kayak cockpits. the foam was then shaped to fit. the glue and the foam was longlasting in saltwater. The thing about automotive door seal products adhesive, its not up to the task.

 

This is my third camper shell on various pickups. The other two never had dust intrusions like this. Some dust is understandable. I get that.

When the door is latched there's still lots of play in the door. It doesn't latch flush enough. I can still fit my pinkie in the door gap on left.

For the door height, you can see from the pics how far off it is. Looks to me like the door was cut too short. (?) 1" on one side 3/4" on the other.

In the last photo, you can see that I added the deep weatherstripping. This is a patch. I can't imagine how bad it would be inside without it! Actually I can...because first trip out everything was dusted out.