Went to a different vw stealer today, most impressed, they spent loads of time on the car, loved my VW licence plate and have booked the car back in for some further replacments under warranty. They did take me out in a nearly new GTI to compare noises and mine was no worse, so I do feel a little better. Re the gap on the inner seals, this is normal and I looked at a few other golfs while at the dealers and they are all the same so no worries.

The dealer are going to try and improve the seal compression on the front doors to restrict the noise further, so fingers crossed.

All in all I'm a tad happier now and will start enjoying the car! Thanks to all for your replys!!!