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Leaking water in from the door sills (rocker panels)??
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Posted by S Carlson [Email] (more from S Carlson) on Thu, 16 May 2024 19:38:01 Share Post by Email
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I had the dreaded floor rust... in a non-sunroof car! I took out the sponge foam and seats and wire wheeled the rust down and coated it with POR15, so that's taken care of. No holes!!

Now I've been hunting leaks. Under the dash seems bone dry, except for an area of foam on the air box that I think is dried mouse pee absorbing water from the air.

The crazy thing is, water appears to be coming in via these little pass-throughs from the floor pan to the door sills (see picture). Like it's coming from the front of the car, under the hood behind the fender, entering the sill box-channel, and flowing out these passages into the floorpan and collecting there. Funny enough, the door sills appear to be coated inside with cosmoline or something similar so they do not seem rusty inside. The drain under the door sill channel is likewise good/unblocked, but the water is entering the floor pan here.

Anybody ever seen this? How do I stop it? Just plug the passage? I believe the tarlike sound deadener was put over these holes from-factory, but water was seeping under it and that's part of what caused the rust in the first place. Do all cars have these? Mine is a 1990 Valmet-built 5-door so it might be weird to the American crowd.

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