Originally Posted by Marcel Huijser
QUESTION: To fix the leak, should I put some Permatex flowable silicone windshield & glass sealer on the top of the black strip and have it seep in where the water did? Or is there something else you would advise?
I'm seeing something completely from what you're describing Marcel---I still think your windshield is leaking. If the second photo with red arrow shows where water comes in that's the windshield bond having failed, albeit very slight at the moment.
Sealing the rubber trim covering the metal track the raised roof installer used to attach the new top to the existing body won't work. That piece you mention is nothing more than a trim part, meant to cover the metal track and screws used.
If there were a leak in the area you suspect a rust trail coming from the visor mounting hole would be evident, the leak showing itself further back on the headliner than your previous photos show.
I think the rust you see outside the van is from the track and screws showing their age---there's no real danger in that though.
There should be a small channel formed between the body and the inside surface of the windshield. If you can force a sealant into that channel, using some sort of plastic tool to make sure you're filling that area, pushing it upward so its forced as far as you can go. A flowable silicone won't work as it wouldn't want to stay in place with one open area for it to flow out of---if that makes sense?
I advise using silicone sealant/adhesive for the DIY whose not overly familiar with these sorts of leaks. Its a forgiving material, easy to work with and if it doesn't do as hoped for won't create any issues with the existing windshield bond.
It may come to be you'll have to have the windshield removed, the pinchweld area cleaned of the existing bonding material as well as any existing rust. From there you'd want to properly treated that area against future rust with the appropriate materials.
Hope this helps Marcel.