Thank You all for your input and advice. This is what I have done. I re-assembled the door using a small bead of clear bathtub silicone…yes, silicone since I have it….on the outside and inside of the u-shaped vinyl gasket on the vertical sides only. The ribs on the gasket are still ok and it fits quite snug in the aluminum frame.
I have some 1/8” heavy rubber gasket material, so I cut some 1/8” square strips and used them to fill the void at the top of the glass. The glass is seated all the way down in the bottom channel, so the weight should be borne by the lower hinge. The rubber strips and the silicone are only meant to keep the framework from sagging again. The glass should never expand enough that the gasket and rubber strips can’t compensate.
The door was about 5/16” out of square on the diagonal before. Now it is 1/16” out of square in a favourable way. I am not sure if we are even going to get to use it this summer, but I will definitely post the results here, good or bad once we have travelled with it.
Thanks again!
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2010 Cougar 26SAB, 2017 F-250 Superduty gas. B&W Companion hitch.
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