Wet drivers footwell but can't get to the hole...

[midlife crisis]

Hi all,

While my T-Bar now seems to have stopped leaking (for the moment at least), I regularly get a wet drivers footwell. I have found the hole, but it is up above the accelerator, pretty high up, only just within reach. I've tried randomly stuffing P40 up there but it's still leaking so I really need to get to it to fill it in properly.

The problem is it seems to be in the panel that is accessed through the long thin slits at the bottom of the windscreen that have plastic mesh covers over them, and aren't big enough to get your hand into. It also seems to me that this panel can't be accessed either from the wheel arch or even if the wing is removed. Does anyone have any idea how I would be able to get to this, other than from inside the car, as it's so hard to get to behind the dash...

All ideas will be very gratefully received...

Thanks! Dave

[LimeyMk1]

For that one I think it'll be a case of either removing the dash or the windscreen.

[MartG]

You could try popping out the plastic grille and squirting some expanding foam filler in there. Trying to fix it from below probably won't work, as the it will be rusting from the outside so will just work its way round whatever you bodge it with

[greglebon]

I can visualise this: I bet its gone right in the corner, too......

What I did with my first Mk1 when it had the same problem is to make a tool from a piece of dowel with P200 wet'n'dry screwed in the end.
If you have small hands you can probably get away without the dowel, but thats up to you...

Use this to remove as much of the rust from around the hole, going in from the top / vent side.
Next, sand around the hole from below: you should be able to do this by hand (if you're a contortionist, or perhaps your other half is an Olympic Gymnast..?! )

Anyway: when you've removed as much rust as poss from the hole, apply some Kurust from the outside with a thin brush.
I would strongly recommend cramming some kitchen roll or cloth under the hole from inside, as Kurust drips easily, and it stains badly ()clothes, carpet, paintwork, etc)...be warned...!

When the Kurust is dry, get yourself some Sikaflex 221 from a local motor factors: alternatively, you could probably use a waterproof Silicone sealant in the tube, but Sikaflex actually sets like rubber, rather than shiny like Silicone sealant.
I have found it to be perfect for car-related fixes, as it sticks like xxxx-to-a-blanket, and is hard when set.
You can even use it to fabricate engine mounts......!

Ok...so now apply the Sikaflex to the hole from above: apply liberally..!
if you cant get the tube in there with the gun, either wear a plastic glove and use your fingers, or apply some to the end of the dowel you used earlier, and use that....

Finally, apply some from underneath, leave for 24 hours to dry...and job done.......

[Jim-SR]

remove the wing, there is then an access panel that has a metal plate covering it with spring clips inside. youll see what i mean, its about 2-3" square. pull it out and it may give you access from the side, depends how high up the hole is.

otherwise youll have to pull the dash out. which isnt as hard as it appears, its just time consuming. with the dash out there is loads of space to play with. the hole will be inside the drain channel where its got clogged up with debris and just rusted through (leaf litter and what not gets in there and turns into compost over time).

expanding foam would be a bad idea. youll block the drain channel even more, and trap more moisture in. it will rot through even worse and leak even more than it does now. you need to fix it properly, or youll be fixing it twice!

[midlife crisis]

I've done a quick fix by cutting some plastic sheet to size to cover the hole. The front boot seal does a good job of holding the sheet in place along the front edge, and it tucks up behind the screen with a bit of gaffer tape. This seems to have stopped the worst of it until I can find time to do it properly.

greglebon, love the ingenuity - you're more committed than me!!! I can't really see what's going on from the top (can't even see the hole) and there's no way my hand's gonna fit through the slot. Think I might go with the dash-out option. I'm used to taking bits of the interior out for various reasons, so shouldn't be hassle, just the time it takes. Gonna wait til it's abit warmer first tho...

Thanks for the tips, and it's good to know I'm not the only one with this problem.....

[Kooga]

What Jim said...do it properly or you'll regret it fast! Dash out the only way to sort that, if there's one hole, you can pretty much guarantee you'll find more with the dash removed. Dash removal takes about 4 hours and is pretty easy really. Remove bad metal, weld up the hold and protect with paint, waxoyl and then use a seam sealer all over the surface to secure your dryness...