After two days in Austin I was told they couldn't get the top to leak. Sure enough the first day back in Tucson:
Again it was coming through the light. I had hoped that with their knowledge of top construction that they would be able to track down the issue- but "We can't get it to leak" was their final answer.
On taking off the light cover I immediately noticed a suspect screw.
I took off the light fixture itself and realized that there were several sizes of screws used. For starters that's weird- obviously someone has replaced screws at one time or another.
But there are 3 long ones and one short, but only one of the long ones was stained with leak on the light (although another one came out with black crud).
The light itself made it obvious there was a problem. I know the SMB guys took off the cover because it was cleaned when they were looking for the leak.
Once removed it was obvious this has been an ongoing problem. There are several positioning stains, the wood panel is all rotted and black and multiple screw holes for each screw. How could you see this and think there is not an ongoing problem?
Now it looks like my choices are 1) take the top apart completely 2) go back to Austin (28 hrs RT) or 3) go to Fresno (22 hrs RT)
The van has been in the dealership 6 times in two months and had a small host of other problems. In addition the rear of the top is Rhino lined over about 3 square feet. I assumed this was an SMB Factory mod for no slip climbing on the roof, but as Paul (SMB Texas) pointed out, it was probably an attempt at addressing the leak.
I'm not sure how the top is put together but it looks like the whole inside needs to come out, as it could be leaking anywhere and settling in the rear over the light. Not a job I want to tackle, plus since the board is rotted inside I can't exactly the ceiling back.
I'm off to call Paul... any ideas are welcome.