Today I also noticed my drivers door seal has failed ...
After careful consideration, maybe we're all misinterpreting what is actually reporting here:
(http://i.imgur.com/8wI2AfN.jpg)
But are there not WAYS of finding out answers without being so blatant in the first place?
Nobody else has joined here with a username so obviously designed as "I am here to get one answer then I am off"
Now to the seal - what is it's job? To prevent water ingress to the vehicle via the hole they put in the side of it to allow us entry / exit when we wish to go somewhere.
What is not it's job? - To be subjected to a rubbing motion upon a part of it that is not supposed to be in contact with anything else other than the door.
How big should a door opening be? - Subjective but on a hatchback sized car within a certain tolerance of what the customer expects with regard to overall length and to accommodate two doors down either side there has to be a maximum and looking at any car in the segment they all tend to be much the same. also factored into this would be the safety cell, indeed many much larger cars would not have much larger openings for that very reason.
BELOW WRITTEN WITH TONGUE IN CHEEK - DO NOT PROCEED IF EASILY OFFENDED!
Should manufacturers include a "vertically challenged option pack"? Booster seat, blocks on the pedals?
How about a "tall person option" - Remove the back seats, spare door seal pack
Wide person option - Remove the passenger seat, spare door seal pack.
How would this be assessed? Would the consumer be happy rolling up to a dealer showroom and being automatically ticked into a certain category who require a certain style of vehicle or options to make it compatible with their body size/shape? Of course they wouldn't, they would be taking you to court, so what do manufacturers do? That's right they make something that fits the average and add or subtract a given tolerance (recognising that this will be OK for the majority of buyers)
Those that have any issues outwith "the norm" (in this case approx. 0.0007%) then need to understand and manage their own expectation, if I am a bit bigger and prone to rubbing the opening edge when I enter and leave then I have to accept that this may be creating a problem which the design was never intended to deal with and which I may have to make a payment for later.
It is no more a design fault than the larger person having a design fault themselves, humans are not created equally, cars are.