Multiple water leaks Discovery 2

nomechanic said:

just had a look. Pulled the firewall away from the corner and had a good look and its clean as a whistle. Regarding any repairs, not sure - depends what I find. Some I might be able to tackle, but if welding is required then I have a couple of options

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Good to hear. Welding in these areas is not a job to take lightly if I’m honest. Having the skills and equipment to tackle this isn’t something most diy mechanics have. Whatever the cause, and I hope it becomes an obvious and easy fix, good luck with it

I had a large rust hole just under the windscreen on the driver side electic glued it up

Good thread and some nice welding.
I am currently trying to solve the same issue: water ingress at the outer edge of both front footwells on my Discovery 2.
On comments about the "inner wing to bulkhead area as a culprit", is this due to water splashing up from the wheel arch while driving in the wet, or is it dripping down from the windscreen area when it is raining? I'm trying to figure out the route water takes when rain lands on the windsreen as, after having the windscreen (badly) replaced, there are gaps aplenty.

Water does get into that spot on 3 sides -
1 condensation / leaks just above the carpet/ insulation, around the weld-point
2 in the wheelarch & partly covered by the liner, which can trap moisture-laden dirt against the joint
3 inside the engine compartment, behind the soundmat which again traps water against the joint

So the painted/welded & seam-sealed joint deteriorates over several years & any opening lets rust take hold & goes unnoticed until its too late & needs serious attention.

Most cars have a weak spot somewhere, D2's are perhaps more noticeable because we want them to last forever.
Many other manufacturers cars seem to only last a decade or so before they're on the verge of being scrapped, whereas Land Rovers are just coming into the age & price range of normal low-budget and DIY owners- like me

Have fun!

Not sure if it also leaks along the seam where the blower intake/wiper motor is under the scuttle panel as they use the same seam sealer as the roof gutters which goes brittle & cracks, the air intake was where mine leaked,see pics.

Meego what is the product you have used here to stick on the floor ?

R-Two-D2 said:

Mine had holes high and low...
View attachment 311990

The low one was easy enough, but the top one was right where the bulkhead met the inner wing.
Managed to weld it up, but was so relieved to be finished I forgot to take pictures.

Relieved as in, loads of smoke but happily, no fire...
Also, Really close to wiring...

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How did you do it where it meets? Repair the inside then the outside and weld just the underside? If you know what I mean?

Bone9 said:

How did you do it where it meets? Repair the inside then the outside and weld just the underside? If you know what I mean?

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I did the patch on engine side first (below the brake servo) but welded it from below as access was easier - partly from the pedals side but mostly from in the wheelarch.

Then I welded the patch below it, mainly from the wheel side but also a few tacks from inside the footwell.

I made (but ended up not using) a patch for the carpet side, but after I'd painted the first two patches, and seam-sealed them, then painted again, and undersealed on the wheel side, it looked such a good fit I decided the carpet-side didn't need a patch so I seam-sealed and painted that, so anyone looking would be able to see it had been done properly, rather than bodged with fibre-glass or something.

I just tried to get some photos with my phone; not the best, sorry...
Couldn't get a carpet-side picture, I need both hands to take the picture then would also need another two to pull the carpet back; my old arthritic fingers can't move that beast very easily....

close-up of new ledge / patch under the servo


rubbish access from above...


looking Up at that new ledge


and the view of the 2nd patch, from above the wheel


I was hoping the ribs might have been a better fit, but looks OK / good enough and the MoT tester said it was neat (and did I want a side job...)

R-Two-D2 said:

I did the patch on engine side first (below the brake servo) but welded it from below as access was easier - partly from the pedals side but mostly from in the wheelarch.

Then I welded the patch below it, mainly from the wheel side but also a few tacks from inside the footwell.

I made (but ended up not using) a patch for the carpet side, but after I'd painted the first two patches, and seam-sealed them, then painted again, and undersealed on the wheel side, it looked such a good fit I decided the carpet-side didn't a patch so I seam-sealed and painted that, so anyone looking would be able to see it had been done properly, rather than bodged with fibre-glass or something.

I just tried to get some photos with my phone; not the best, sorry...
Couldn't get a carpet-side picture, I need both hands to take the picture then would also need another two to pull the carpet back; my old arthritic fingers can't move that beast very easily....

close-up of new ledge / patch under the servo
View attachment 313140

rubbish access from above...
View attachment 313141

looking Up at that new ledge
View attachment 313142

and the view of the 2nd patch, from above the wheel
View attachment 313143

I was hoping the ribs might have been a better fit, but looks OK / good enough and the MoT tester said it was neat (and did I want a side job...)

Click to expand...

That's great, thanks buddy. Nice job.