Finally a sealed passenger compartment

[Kurt]

I finally found and fixed the remaining pesky water leak into the passenger compartment. This is the 1st time since owning this car (28 years) that it does not leak from somewhere. I have resealed the windshield, back glass, trunk seal, door seals, & window seals over the years. This last leak eluded my for the longest time. Water would end up on the front passenger floorboard after washing the car. Thinking it was still the windshield I pulled the dash pad and had a friend pour water around the windshield while looked to see where it was getting in. No leaks! That was great news since the windshield was a total b!+$# to seal. He then poured water into the cowl grill and bingo here it peed onto the floorboard. Come to find out there is a gasket that seals the firewall to the a/c evaporator housing there. The gasket shrunk leaving a gap where the water was entering. Replacing the gasket would require pulling the a/c/heater assembly off the firewall which is no fun. I have replaced a few heater cores in my day and it totally sucks. I instead opted to fill the gap with some sealer. It was very difficult to get the sealer where it needed to go. I ended up attaching a hose to my caulking gun to get the job done. It took a few tries but eventually I got it to where I can't see any light shining through the gap. I gave it a water test and so far so good.

Here's where it was getting in. The gap is on the opposite side but

impossible to photograph

My customl tool

 

I found some interesting things in the cowl: a scotch bright pad and a couple
pieces of sand paper. That darn painter!

Although I would not rather drive the car in the rain, It's great to know that I can do so and wash the car without having to worry about it getting wet inside, getting moldy, smelly, rusty etc. Of course this has spawned new projects like get the wipers and washer in tip top shape as you might have read in my other post. Never a dull moment...