Multiple water leaks Discovery 2

hi all, been a while since I posted. I hope your Disco's haven't cleaned you out like mine continues to do. Despite the love and care I show for this thing and regardless of how much money I throw at it, it gives me new problems weekly.
Appreciate this topic has been done to death but I have recently noticed the front footwell carpets getting wet and am struggling to interpret what I am seeing, as it is not the same as the other posts I have researched op the topic.
I have taken the carpets out and they are drying but trying to trace the leaks is proving troublesome. I can see where it is coming into the cab but interpreting where it is coming from is my issue and wondered if you guys could give me a view please.
Leak 1: Drivers side (UK) front footwell. In the corner behind accelerator pedal. Just slightly seeping in.
Leak 2: Drivers side (UK) front footwell where the door seal meets the floor (I can't decide if the door seal is faulty (have ordered new ones in case), or it it is a false positive and its coming from the roof or something and just looks like the door seal
Leak 3: Passenger side (UK) seeping through a seam below a bolt that supports the dash (near the bonnet release catch).
I have dropped the bonnet, removed the cowl and wipers etc and all looks tidy. The drains into the wing appear to be functioning but there is no corrosion/holes around the bottom of the screen.
I have taken the passenger side interior A pillar trim off and cant see anything obvious.
I am due to get the headlining relined soon and so will replace the seals for the roof rails at the same time.
Thanks in advance

Inner wing/floorpan/bulkhead rotten. Peel back the sound proofing and take a look. Been a few posts on this here, over the past few weeks.

I replied to one! With pics attached

Kev

thanks Kev will take a look

I second the inner wing to bulkhead area as a culprit. Pull back the foam sound deadening and have a look where the loom goes through the bulkhead on both sides. The deadening traps crap and moisture in the corners and encourages rot.

This is what I found and how I dealt with it.

meego said:

This is what I found and how I dealt with it.
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thanks for sending these through. Just so I am clear what I am looking at in your pictures, how high up have you had to cut out the rot and weld in new metal? I have taken the front carpets out of mine and had a look up behind the dash and it looks clean

Mine had holes high and low...


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...

nomechanic said:

thanks for sending these through. Just so I am clear what I am looking at in your pictures, how high up have you had to cut out the rot and weld in new metal? I have taken the front carpets out of mine and had a look up behind the dash and it looks clean

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It sounds as if you’re lucky and it’s not as bad as mine was then. When you look up behind the dash, you can see the oval hole where the main loom comes through. That’s were my leak originated.

Hi if you happy you dont have any rust after removing the front cowl, check the grommet were the wikring loom goes through mine looke Ok but were loss and needed a reseal

meego said:

This is what I found and how I dealt with it.
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Looks brilliant mate

And the same places as mine

Good work.

Kev

nomechanic said:

thanks for sending these through. Just so I am clear what I am looking at in your pictures, how high up have you had to cut out the rot and weld in new metal? I have taken the front carpets out of mine and had a look up behind the dash and it looks clean

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When you have cleared the area! You should be able to see where you need to go!
As for cleaning the rot! Take it back to clean steel? (Your looking at minimum 10mm clean steel for your plate/patch)

Kev

meego said:

It sounds as if you’re lucky and it’s not as bad as mine was then. When you look up behind the dash, you can see the oval hole where the main loom comes through. That’s were my leak originated.

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thanks. Will post some pictures tomorrow but I can't see any corrosion at all. Will double check the grommet for the loom too.

frostythor said:

Hi if you happy you dont have any rust after removing the front cowl, check the grommet were the wikring loom goes through mine looke Ok but were loss and needed a reseal

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had the cowl off. Absolutely no rust there at all

nomechanic said:

had the cowl off. Absolutely no rust there at all

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but will check the grommet again - thanks

nomechanic said:

had the cowl off. Absolutely no rust there at all

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Where we’re talking about is below that. That’s the scuttle panel. Go to the passenger side in the engine bay and you will see the aluminium valve block for the ABS system. Down in the corner beneath that where the inner wing wheel arch meets the bulkhead, you will see where the loom goes through the bulkhead. I had to cut away where it levels out so I could get to the area from in the near side wheel arch.

meego said:

Where we’re talking about is below that. That’s the scuttle panel. Go to the passenger side in the engine bay and you will see the aluminium valve block for the ABS system. Down in the corner beneath that where the inner wing wheel arch meets the bulkhead, you will see where the loom goes through the bulkhead. I had to cut away where it levels out so I could get to the area from in the near side wheel arch.

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noted. As my username might suggest, I have no idea what I am doing but armed with the Haynes and Rave manuals with some online 'tuition' I am giving it ago. Will take a look at that tomorrow. Do I need to remove anything else to see it ?

nomechanic said:

noted. As my username might suggest, I have no idea what I am doing but armed with the Haynes and Rave manuals with some online 'tuition' I am giving it ago. Will take a look at that tomorrow. Do I need to remove anything else to see it ?

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If you put your hand down into that corner, you will feel the soft vinyl covered foam sound deadening. It’s about an inch thick. Pull that away from the bulkhead and you will see the loom going through a horizontal oval hole. It’s in my photo with the white repair panel already welded in, but that photo is from below with part of the inner wing cut away. If you do find rust and holes, what’s your plan to repair it ??

I don't know how different the Disco 2 is, but on my Disco 1, the base of the pillar has a big hole, that was filled with sealer when new... then it cracks and lets water in. It's about where the Yellow arrow is on this pic I stole from above:


The Red arrow, is another spot where the sealer cracks on the Disco 1 and water runs into the cavity that's behind/below the hinges, and runs to the ends, then into footwells similar to this other photo I stole from above:



As I say - I have never touched a Disco 2, so it might be different, but the hinge area and the seam beside it look remarkably the same... but the pillar hole me have been done away with, when they changed the pillars and fitted the plastic outers.

meego said:

If you put your hand down into that corner, you will feel the soft vinyl covered foam sound deadening. It’s about an inch thick. Pull that away from the bulkhead and you will see the loom going through a horizontal oval hole. It’s in my photo with the white repair panel already welded in, but that photo is from below with part of the inner wing cut away. If you do find rust and holes, what’s your plan to repair it ??

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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