Disco roof leak

bigrichsri · Jan 27, 2012

Took all of the rear trim panels out of my disco today to weld in new arches and plate some holes in the floor caused by the lake that is the boot. Decided to find out where the water was getting in, removed and resealed the alpine window which did bugger all. Took headlining out - all dry. It seems to be getting in to the box section below the alpine window which makes me think it's coming through the gutter somehow. I removed the trim from the gutter and it all looks ok, can't see any cracks in the filler.

I've read somewhere that someone drilled holes in the gutter to stop water build up. Is this a good idea? I don't want to make it worse by making an easier route to the seam.

1spin · Jan 27, 2012

trayback it, job done...

GreenHornet · Jan 28, 2012

I may be wrong so forgive me if i am.

The roof panels are pressed with the gutter as one piece and I believe the issue of the lower panel rusting away is quite common, not helped if the alpine windows are leaking too. Then of course you have the rear washer pipe running through the top of the interior so that needs a hole to exit which creates another potential leaking point.

It's not impossible to have rainwater or driving spray going inbetweener the gutter joints and then rotting away the interior. The problem is that the ingress could be at the front and then running through the seam to the rear.

Sorry that I couldnt give a more definitive answer. All you can do is trace the rust to its highest or furthest point and go from there.

dyte · Jan 28, 2012

The roof is separate from the gutter but the bit you see rusting is the same bit that wraps to form the gutter tiny holes at the bottom of the roof line cause eaks and the inside rots

grunta-22 · Feb 4, 2013

I have the exact same problem. replaced boot floor after buying the car then found out why it rusted away in the first place when brand new replacement rear speakers i fitted started to blow because water was dripping down them and onto the floor.

Blamed the alpine windows and promptly removed and resealed but still finding that water is getting in. Always had a sneaking suspicion that it was getting in through the gutters somehow but could never find where.

bigrichsri did you find where yours was getting in. Does anyone else have any ideas?

Steve2a · Feb 4, 2013

A previous disco of mine was exactly the same, if you look at the gutter going over the rear door and around both rear corners of the car its 2 pieces pressed together, I found sealing this up stopped the leak, then the rusty mess you see there got dry enough to be treated and filled

GreenHornet · Feb 4, 2013

dyte said:
The roof is separate from the gutter but the bit you see rusting is the same bit that wraps to form the gutter tiny holes at the bottom of the roof line cause eaks and the inside rots

Don't think it is, the gutter is used as a fixing flange. Gutters are then seam sealed in the factory.

Seam sealer dries over time, splits and then water gets in and tadaa

olliedog12000 · Feb 4, 2013

GreenHornet said:
I may be wrong so forgive me if i am.

The roof panels are pressed with the gutter as one piece and I believe the issue of the lower panel rusting away is quite common, not helped if the alpine windows are leaking too. Then of course you have the rear washer pipe running through the top of the interior so that needs a hole to exit which creates another potential leaking point.

It's not impossible to have rainwater or driving spray going inbetweener the gutter joints and then rotting away the interior. The problem is that the ingress could be at the front and then running through the seam to the rear.

Sorry that I couldnt give a more definitive answer. All you can do is trace the rust to its highest or furthest point and go from there.

Just wondering do you know if the wash hose runs on the drivers side of the car? I have sealed my sunnys and checked the alpines but the other day my boy shouted that he was getting dripped on and after reading this comment I realised I tried the rear wash but thought it was blocked and that was the day he moaned at me.

StuRox · Feb 5, 2013

I have the same problem...

http://www.landyzone.co.uk/lz/f8/mission-impossible-water-leak-boot-196994.html

Still leaks, never found where it gets in, and believe me, I went through some tiger seal trying to stop it - all I know is that if I park facing downhill, it will leak, face uphill - no leak - so that's how I park, and no leak

Not the best of fixes - but it works!

discool · Feb 5, 2013

olliedog12000 said:
Just wondering do you know if the wash hose runs on the drivers side of the car? I have sealed my sunnys and checked the alpines but the other day my boy shouted that he was getting dripped on and after reading this comment I realised I tried the rear wash but thought it was blocked and that was the day he moaned at me.

As you can see in the first pic above the rear screen washer hose is on the left or near side, logical as that side you have the washer fluid bottle and also the jet..

Disco roof leak

bigrichsri

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1spin

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GreenHornet

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dyte

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grunta-22

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Steve2a

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GreenHornet

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olliedog12000

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StuRox

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discool

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