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[924RACR]

So I just identified and resolved a new flavor of sunroof leakage on my 82 931.

Just to recap the most common sources of leakage, step one is to blow out the drains (ideally with compressed air - and accessing from the bottom end of the drain tube is easiest). I had done this previously, but did have some blockage as it's been quite some time.

Another helpful step is to replace the seals, which I had also done quite some time ago (maybe 15-20 years, maybe longer ago). There's a very expensive one - around $140USD as of this writing - that attaches to the edge of the sunroof panel itself, and a very cheap edging that goes around on the edge of the metal body (maybe $20 from the dealer right now).

I had even taken the step to glue the drain hoses to the metal ports at the corners of the roof with some RTV silicone, to prevent any chance of leaking (which did work).

But I still had some water coming in on one corner. Peeling back the headliner, I realized it wasn't coming from a leaking hose, nor from the actual edge of the roof - but from somewhere on the metal out of sight up above...

Then I investigated the corner at the drain... and I think I noticed that there was a little bit of corrosion and maybe a pinhole where body sealer was used to join the metal of the drain spout to the edge channel in the roof.

So using a toothpick I added a small amount of body seam patch - I used POR15's product, which can be put directly over rust - and caulked the surfaces, sealing in any corrosion and being sure to fully cover any edges to seal fully.

Here's the product I used:
https://por15.com/collections/fillers-and-putty/products/patch

After some horrendous rains last night - well, I still am withholding certainty of a fix, but there's nary a drop in the inside, whereas previously my driver's seat edge would be soaked.

Something to consider if you're chasing a persistent sunroof leak...

Now I can confidently get my headliner replaced without worrying about it being immediately damaged.

Next and hopefully final leak: the drain tube above the driver's footbox, which leaks directly on the accelerator pedal wetting down your right foot...
_________________
Vaughan Scott
Webmeister
'79 924 #77 SCCA H Prod racecar
'82 931 Plat. Silver
#25 Hidari Firefly P2 sports prototype

[924RACR]

Update on this - we had torrential rains yesterday in the midwest, and I was up and about in the 931 between the worst gaps... and no leaks on the driver's side! Fix is confirmed...

Now to deal with the passenger side, which has leaks front and rear!
_________________
Vaughan Scott
Webmeister
'79 924 #77 SCCA H Prod racecar
'82 931 Plat. Silver
#25 Hidari Firefly P2 sports prototype

[morghen]

Nowadays i'm happy with a non-sunroof car
But thanks for sharing.
_________________
Supercharger and EFI kits
https://www.the924.com

[924RACR]

Another update - went and did the other three corners, with subsequent rain to verify no more leaks from any corner! Much happiness; now just have to fix that driver's foot leak and the car will be properly dry for the first time in decades...
_________________
Vaughan Scott
Webmeister
'79 924 #77 SCCA H Prod racecar
'82 931 Plat. Silver
#25 Hidari Firefly P2 sports prototype