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Thon

Member Since: 22 Nov 2015
Location: Salisbury Plain
Posts: 696

Windscreen frame leak - any ideas on repairing in situ?

Hello and welcome, oh learned and venerable leak-rectification practitioners

I have recently discovered that after a full roof off and roll cage fitting, where every single seal was replaced (successfully), I now have a leak into both front footwells from the windscreen frame.

The lower gutter part of the frame is constructed from 3 pieces - a long central gutter and 2 end pieces, and it seems that the join between these pieces has decided to leak. I have filmed it literally running through the join on one side and can only presume that it is the same problem on the other. You can just see the bumps of the misaligned pieces of the gutter on the pic below:

Due to the added complication of the roll cage, lifting the roof an inch is not possible as the roof seam bolts are hidden by the cage (it is internal/external). I would have to remove most of the roll cage in order to do this, and as all of the seals have already been re-sealed successfully I don't really relish doing this (or paying someone else to do it).

Click image to enlarge

My question boils down to this: I am hoping to pull the dashboard out to access the seams/joints and then use some kind of sealant to render it waterproof again on the internal face. I can pop the screen out easily, but obviously the dash is a little more involved, so I want to be sure of a proven method in advance.

What method would you recommend and what materials would you use? Hoping someone with some similar experience might be able to make some suggestions.

Thanks in advance!

8th Oct 2017 9:46pm

Harry.O

Member Since: 25 Jul 2014
Location: Warwickshire
Posts: 713

For small gaps, I've had good results with Captain Tolley's crack cure. It sorted the windscreen seal and hinge blocks nicely. For the seals around the waistline and under the roof gutter, I masked it up and applied a thin bead of Sikaflex and that seems to have held up also. 2005 Td5 110 Hardtop
1989 300Tdi 90 Soft top
1992 200Tdi 90 Truck cab with Land Cruiser axles

9th Oct 2017 9:19am

Thon

Member Since: 22 Nov 2015
Location: Salisbury Plain
Posts: 696

Harry - thank you for the tip - it looks ideal for this kind of hairline crack. Definitely worth trying before I pull the dash out as I can apply it from the outside too!

9th Oct 2017 5:58pm

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