Has anyone had this issue before.

I'm running a fully sealed and deadened door, with the Mids playing down to 63Hz (with a 24Db/Octave slope..) They have a considerable ( ;) ) amount of Bass coming out of there, and at the highest volume there is a nasty rattle that come from the outer handle and its inner assembly.
That includes the pull rods etc.
I've used deadener on the rods to give them more mass and some dense fibre fill to slide between them.
But I just cant shake the very last of the noise.
The rest of the door is noise free, unless I up the gains some more, but I don't need to do that.. ( trust me, its kicking now)

Can anyone offer me any help please?

There are 3 bolts bolting the handle to the door.

There is really no packing deadener made of foam between the handle and the thin sheet steel.

take the handle off and then place a thin layer of a foam substance between the plastic washer for the handle and the steel, and another very thin strategic layer between the handle and the washer itself.

Also commonly, the self adhering foam block for the lock rods, are easily affected by water in later models. So they come off.

Mike

I had a real issue with running my Usher's in the door, I have a constant rattle but I removed my exterior door handle but it didnt help, then with the noise from the trim itself and manual window crank I gave up and went floor pods lol.

Seriously though wrapping the lock rods in a serious amount of electrical tape works well, a little bit of deadner on the plastic clips that hold the lock rods to the handle will help aswell.