I used a door on a custom jamb to handle the extra thickness of the DW, clips, and channel, so my door is flush with the interior jamb. At any rate, I'll probably order a Zero seal and put it on the push side.
I have managed to get my dead vent finished up. The pictures are horrible because it's such an small space to try to get into, but I know how you guys are. First a little framing:
Then some insulation, and the first bit of drywall:
And the finished product:
Since I had to have a removable panel for access to my junction box and fan, I used a layer of 5/8" ply, and put strips where my studs are to give me something to put screws through. If I expected to be in there more often I might have gone with something that would hold up to repeated installation and removals, but I think this will be good for what I need. I filled in the space between strips with 5/8" drywall since it's heavier. It's not pretty, but that part of my equipment closet is not likely to get finished......... ever! I'm planning a removable panel between the rack and the wall there to allow access to the back. With the cover on there, the fan is just barely audible, and is certainly quieter than the jet engine I have for a server.
The bad news, however, is there is quite a bit of wind noise at the opening into the theater. Now that my door seals (extremely) well, I can't hear my server in the theater anymore, but it makes it painfully obvious just how much wind noise I'm getting at the return opening. I'm hoping once I put my soffits up I can duct the vent around to the back of my theater, and give it a large opening to get the velocity down. If that doesn't work, I'll probably be looking for a new fan since this one can't be slowed down.