Passenger Door Rattle

Recently I dismantled the passenger door due to a rattle from the carpeted speaker area....I followed all the guides I could find on what seems to be a fairly common fault and tightened everything up loctited etc and the problem stopped. Unfortunately the rattle is back only at low Revs but it's annoying when stopped at traffic lights etc. If you hold the outside black speaker frame or the carpeted area close to the speaker the rattle stops so this has got me thinking could it be the outer speaker cover rattling against the inner speaker unit ( see pics below) ? So does anyone have any suggestions to cure this rattle ? Thanks as always for any suggestions

Did you cut open the foam? There is usually a loose screw directly below the two bolts on the right hand side of the air bag bracket (about 3-4 inches below). I cut a slit in the foam and then sealed it back up.

Yes removed the foam backing and tightened everything I could find underneath. The cars done no more than about 100 miles since I did this work hence I don't think anything could have come loose again so quickly. So that's what prompted me to think what else could be causing this rattle.

Check to see if the window cable mechanism is tie wrapped to the door panel. This is a thick har cable that will rattle and vibrate against the door panel is not tie wrapped down,. This is done from the factory, and when i replaced the window cables I then acquired this rattle...

My door started rattling since I removed the plastic screw fastener inside the door bin. I've not got round to replacing it yet, but it's very hidden away inside the pocket so you may have missed it if it's not there?

It's not that awful plastic screw inside the door bin as I had to end up drilling it out as the head just rounded off. Haven't really had time to do further investigation but the rattle comes and goes but always at low revs and always from around the carpeted area that covers the speaker box.

I've not yet had to drill out that screw but i agree .. they are a pain in the butt to remove .. metal trim tool .. a small V shape on the end is what i tend to use to pry it out . Door noises .. the common one is the speaker box rear screw coming loose .. you have checked yours so moving swiftly on .. I had one a few weeks back .. noise in the speaker area .. the window reg has a lower stop .. this is adjustable for different models and is held in place by a T20 screw .. it was loose ... this is behind the speaker . If you pull or push the door panel and it stops then logically it is the door panel .. Door card off , refit the handle trim you removed to get the T30 screws out .. this stops the clips from rattling .. Palm of hand and bash .. not the right word but gently hit the door card .. anything obvious and look at where its coming from . Same on the door itself . Door cards have plastic welds .. 997 certainly do , can't remember off hand a 996 but i think that speaker cover is removable .. if so it can come loose .. Lastly .. the door card clips .. old and tired and they will be loose .. always worth replacing them for a tight fitting door card .. this can stop noises . Noises come and go depending on rpm .. it's a frequency thing .. harmonics .. but that stuff is well above my pay grade to understand !!