Repair Question: Water Leak..Suspect Windshield Seal

Boxer_Airhead · 02:31 PM

Sorry, long story for a short answer! I just really need advice.

A week and a half ago I drove my '81 SC to work in the rain. It sat in the parking lot for about 8 hours. The rain was on and off all day. When I returned to my car after work it was raining. I opened the driver's door and there was a small pancake sized puddle of water on the edge of my seat closest to the steering wheel. I drove the car home in the rain, a one hour drive. Water was slowly seeping in right where the headliner meets the leather on the driver's side door frame, so basically the metal frame between the windshield and the driver's door.

I stopped on the way home at my mechanic's and he looked over my door, sunroof and windshield seals. He thought they all looked to be in good condition and even the roof drains for the sunroof were uncloged.
So based on where I told him the water was coming in, he said it was probably a windshield seal leak.

I have since taken the car to a self serve car wash and used a high power hose and sprayed the car for several minutes on each seal using varying pressure and distances. My wife sat in the car to watch for a leak and no water ever penetrated inside the car.

I am very certain that when the leak occured my window, sunroof and driver's door were closed properly.

So why can't I simulate the leak with a hose?

My mechanic also said that even if the windshield seal leaks on the bottom, the water could rise up and leak inside from up higher.

So maybe with the rain water puddling up at the bottom corner of my windshield is where water slowly started to leak in from but came inside up higher?

I want to correct the problem, but want to make sure of what caused the leak before I pay someone to start replacing seals. I have an appointment later in the week to have a glass repair shop pull off my winshield seal and remount it, they will guarantee it not to leak forever if they do that ($200 labor). Assuming they don't ruin my existing seal they will reuse it also.

Or since I can't replicate the leak with a hose, would it be worth it to just have the glass company squirt silicone/caulk (not sure what they really use) under the seal? They won't guarantee that work, but it would be much cheaper. But I also think it would make a mess for the next time the windshield is removed.

Any advice would be helpful.

Thanks and Happy New Year to all you Pelicans,

Myles

Boxer_Airhead · 12-31-2006, 02:50 PM

Here is a picture showing where the water was leaking into the interior:

The water came in between the headliner and the leather on the frame.

Shawn 357 · 12-31-2006, 03:14 PM

you may want to check for the leak with a garden hose rather than a pressure washer....my sc was leaking but didn't show when you sprayed it with a pressure washer. Turned out that my sunroof was not closing completely even though it looke likeit was closed properly (one cable had come undone). Hope this helps.

Boxer_Airhead · 12-31-2006, 06:47 PM

Shawn, thanks for the testing advice. I have really nasty hard-water at my house so I will try a hose at a friends house.

Regarding your leak. Where did the water enter in the interior?

-Myles

Shawn 357 · 12-31-2006, 08:48 PM

Myles,
I never took the time to pinpoint where it was entering the car but if I remember correctly the front left of my drivers seat and subsequently the carpet were getting wet. The cause of my leaks became very apparent as soon as I tried using the sunroof because it would only open part way and then bind. I hope your leak is as easy to fix as mine was...

pozee · 01-01-2007, 05:47 AM

You may want to check the gap around the door frame (where it mates up to the roof line) because it is possible that the water is coming through there and travelling to the location you pointed out in your image. I had a similar issue - I took a strip of paper and closed the door over the paper. Found it was easy to pull the paper in an area about 3" across around the top middle of the door. That is where I found the water to be coming in between the door frame and rubber gasket. Came in over the top of the drip rail and snaked in!

Good luck.

William930t · 01-01-2007, 06:05 AM

Does the windshield seal show gaps in the frame at the upper or lower corners? The seal shrinks over time, a common problem including mine. No visible leaks on mine, yet.

If windshield comes out, be prepared for some (hopefully) minor rust repair in the channel. Don't forget to use a new OEM German seal. The installer better be experienced in Porsche windshields, too.

Keep us posted on your leak detection, thanks

Boxer_Airhead · 01-01-2007, 06:17 PM

Thanks for the great responses.

Pozee, the paper idea was a good one. I tested the paper on the door and overall my seal has good grip all around.

William930t, my windshield seal does not really show gaps anywhere.

Well, I tested with a hose today for like 20 minutes. I could not get any water to leak into my interior. What the heck I am confused. I did notice that water seeps through my sunroof seal but drains well out of the drain holes, so I don't think that is the problem.

For now I will cancel my appointment with the glass repair company. It is supposed to rain here on Thursday, so I will use that day to test further.

Hopefully it was a fluke, I want to concentrate on other 911 projects.

defcon65 · 01-04-2007, 08:46 AM

I think the sunroof seals are more likely to leak than a factory windshield gasket in good condition. Sometimes the water doesn't come out directly below where the leak is, just like on a house roof.
I have repaired leaky window gaskets before with a small bead of clear silicon sealant applied with a skinny applicator tip under the outside sealing flange of the gasket. It's easier to do in warm weather when the gasket is pliable and more easily pulled back. You may have to use a sharpened popsicle stick or plastic knife to get under the edge at first. A good. cheap fix, much less than $200.

Hope that helps.

Boxer_Airhead · 01-04-2007, 04:15 PM

defcon65, I think the sunroof has to be the problem. Simply because that is the only seal that lets water through it when I test with a hose. Granted the roof drains eliminate the leaking water when I test.

I am planning to replace the sunroof seal as soon an I place my next Pelican Parts order.

I will post my results when I get that far.

Thanks again!