OK, I removed the cowl and wipers and wiper motor. Just below the lower corners of the windshield I pushed the rust out to form a hole the size of a quarter into the interior. I want to seal this up but not sure what to use. Don't worry since it won't be seen. Any ideas?

This is a dumb design because the lowest point is where water settles and it's in this area.

 

So I took out the rusty parts and I created some holes in the trough/gutter below the cowl. I plugged up these holes with a piece of aluminum and some plastic metal by Bondo. I'll see if it leaks tonight. Here's some pics.

 

Well it passed the water test (pouring into the cowl), but after the wife drove it, the floor is freshly wet again!!!

Oh well, time to take the front fender off and see if I can find it there. First I must do more evasive water tests. I'll let you all know what I find.

 

Ok, I removed the left front fender last night and I could spot a huge rust hole. Take a look at the following pic:


Inside the larger oval shaped access hole you will see rust. You see where that funny looking bracket is located? Its right below that. I put a screwdriver through that and it goes into driver's side footwell on the left wall. I cut out a piece of aluminum and put some plastic metal on it and pushed it onto the hole followed by more gobs of plastic metal by Bondo. It still leaks but I don't think it leaks as bad. I plan on maybe taking out the dash so I can spot other areas inside the driver's side footwell.

BTW the second page of that first one I posted is below:


This is one area where the oil sprayers can not get to or they forgot to get too. Anyhow, water in the car is not fun and is very hard to fix because usually it only leaks when you drive and not when you pour water over it.

 

Well, I finally fixed it last night, at least I hope. The hole was in the side wall way up under the dash. To get to that spot, I had to remove the dashboard. Of course before that I had to remove the stereo, heater controls, glovebox, hazard flasher switch and other switches, steering wheel, indicator light controls, center console, ashtray and oh yeah the seats.

In total I spent 4 hours fixing this issue. I used liquid metal to seal it from the inside. There was no way I could reach it from the fender side since access is limited. I'll keep my fingers crossed next time it rains.... Right now I just want to sleep. :sleep:

 

any news on the job you did? did it work?

 

yea i used to have mystery water in one of my cars as well and it drove me nuts