I'm very annoyed by this stupid twopart design of the door cards. Half plastic, half cardboard crap and joined by loose plastic pegs of some sorts. Many vibrations and rattles from all over when you go even above 15 on the volume. I was thinking about fibreglass all over the rear of the card to make it stiff? And for good measure, sound deadening foil all over the door itself? Also, a layer of something rubbery between the speaker/door contact patch?

If anyone dealt with this problem before and could enlighten me...I'd be very grateful.

EDIT: A 3dr Stilo ofc. Doors long as f**k.

I get rattles from my doors as well, not so much the door card I get rattles coming from the door lock pin which really bugs me! When I can be bothered taking the door card off to check it ill probably wrap some sticky back foam round the base to mute the rattle. I don't get rattles from anywhere else, what you should do is press the door card in at different points to see where abouts it mutes itself then if probably put sound deadening behind it - better than fiberglass I think?

The door card is very flimsy in design, if I had a penny for every Stilo 3dr I've seen with a busted grab handle and a meter of play between the plastic and the cardboard...i'd be able to buy new doorcards from FIAT. Oh, and to drown out the rattling, I need to put all 100kg of me against the whole door. It's hopeless.

I think that it does need something to tie it all together. Like another layer of reinforcement. That way tha vibration can get dispursed all around and drown. Adding sound deadening to the metal can only further minimise it all.

Remove the doorcard and you'll see the various fixing points. I took a soldering iron to mine and tightened up all the connection points by slightly melting the plastic to form a tighter bond. Deffo improved things...

Oh wow, that didn't even occur to me. How about this: melt it slowly and whilst it's all nice and soggy, also apply hot glue? Like, in copious amounts?

I've been looking at these plastic pegs and some are broken too.

Yes melt things with a soldering iron.
Then to stop internal rattles I use acoustic foam underneath wires and the components attached to the inner door skin.

Then I use a product called cloud 9 to line the inside of the door skin. This acts as a noise barrier and causes a nice soft interferance fit to stop things rattling on each other.
http://www.ebay.co.uk/itm/1-Roll-Of...pet-Underlay-10mm-Thick-15-07m2-/291040783074