One of the last leaks up front came from the big fusebox bulkhead gasket. It must have shrunk just enough over the last 20 years to let water seep in now
Using a tool to confirm the location of the point of entry
So how is water getting there? Well there is this tiny gap you can see underneath the hood gasket
Gap shown with gasket removed
Rainwater will run down the side of the car, drip through the opening, run underneath the fusebox and down the outside of the front strut tower where it eventually meets the side of the fusebox bulkhead gasket.
Since the gasket is not sealing the water will just seep through over time and enter the cabin.
So I began by removing these remnant pieces of sound deadening from fusebox area. Doesn't do much except hide dirt and debris and wait for rust to form
What it looks like with the sound deadening removed and you can see all the dirt built up underneath it. If you look carefully at the lower center part of the image you can make of the bulkhead gasket.
Path of water flow from the above gap to the edge of the gasket is shown with the red arrows.
I don't have a before picture but there was a lot of debris built up in the gap you see in the image below.
To seal up the edges of the bulkhead I used Proform PF224 urethane based body sealant
My very special tools to do the job
I pumped in a bunch of the sealant into the gap and then proceeded to smooth a bead of it around the entire edge of the gasket.
Obviously the caulking gun will not access the area, so putting small amounts on a gloved fingertip and smearing it into place it how it was done.