521 cab leaks

[Tucson620]

Found other threads like this one: https://ratsun.net/topic/37800-521-leak-spots/ with helpful reference to mklotz70 Mend thread. But could use some help. Floor boards are suffering. Forget the carpet kit idea for now.

 

Garden hose testing shows multiple leaks, but the damning ones were three screw holes under the kick panels. And window rubbers, quarter glass too.

 

From mklotz70's thread - what's supposed to stop water coming in these holes (see pic)? Have kick panel screws into two of them, but still leak.

 

And I bought and installed ebay Thailand window felts, squeegees, and quarter glass rubbers. Felts seem ok. But the squeegees didn't fit worth a damn, had to modify to even come close. And quarter window rubbers don't seal either. Water just pours down into the doors and inside across door cards. Is there a good source for these? Successful technique tips?

 

Am familiar with the cab seams at lower corners of windshield. No leaks there since new windshield and front/rear window rubbers. Roof drip rail seam is another problem area - need seam sealer attention.

Edited May 7, 2023 by Tucson620

[mklotz70]

Sorry. I have no clue what the 3 holes are for.  Maybe something was attached to the inside?  Look in the factory parts manual.  Maybe it shows something attached there.  

[Stoffregen Motorsports]

Use plastic or rubber plugs to fill those holes. Or better yet, weld them up.

[Tucson620]

Thanks for input.  2 of them are kick panel screws. On the passenger side, the other is for parcel shelf. Not sure the driver side.

 

Point is they're leaking even when the screw is in place.

Will figure it out. Multiple leaks to address.

[mklotz70]

Since the same sheet metal is used for left and right hand drive, they could be for the same purpose, but on a RHD version.

 

[Stoffregen Motorsports]

Put some RTV on the screw threads, or use a grommet/o-ring/sealing washer on the fastener, behind the panel.

 

Better yet, weld some machine screw nuts on the back of the kick panel before you put the fenders back on, then use small machine screws to fasten the interior panels onto.

 

I use these - https://www.mcmaster.com/products/tab-weld-nuts/