It really rained hard here today with temp
at or near 60 degrees F.  NO LEAK from my
windshield, 0, zilch.  I think I finally got
it completely sealed.
There was a post yesterday stating that maybe my
windshield seal channel was rusted with a couple of
holes.  That is not the case.  I have no rust on
my Vanagon.  The problem originated when my windshield
cracked and I had my insurance company replace the
Vanagon windshield.  The company that replaced the
windshield used a common 1 piece seal that fit rather
loosely in the windshield channel. In fact when I was
injecting silicone sealant between the seal and the
body channel there seemed to be at least 1/16" gap
between the seal(inside) and the body. I made sure
to get a real good bead of silicone around the entire
perimeter of the seal. Had I used an original VW
windshield seal I may not have experienced this problem.
Anyway, rain water was getting in at the top corners
and running down along the channel and dripping on
the floor mats. The seal the guy used just didn't fit tight enough.

Like I said, I used a DULL butter knife to pry
the out side edge of the seal up away from the
body. I angled the butter knife and used it to
LEAD ahead of the silicone tip. This way I was
able to force the silicone plastic tip in between the seal
and the body. I never touched the body with the
butter knife. I exerted force on the seal up and away
from the body exposing the windshield channel.

Make sure your seal and windshield channel are completely
dry before using silicone. I used isopropyl alcohol
and compressed air to dry the water up.  You can also
use contact cleaner or small amounts of Coleman fuel
as it contains a drying agent and (NO SMOKING)
dries up real fast. It must be exposed to warm dry air
to get it completely clean and dry. If the windshield
channel is dirty or wet the sealant won't adhere to the
metal and neoprene seal.

Jerry
88 GL BUS-ter

-----Original Message-----
From: Rob [mailto:becida@comcast.net]
Sent: Thursday, January 04, 2007 11:28 PM
To: Jerry
Subject: Re: LEAKING WINDSHIELD SEAL (p-mail)

Hi Jerry,
I have the same leak, really looking forward to how it works out for
you after the next rain.

Rob
becida@comcast.net
In wet wet wet western Washington State.

At  1/4/2007 04:16 PM,Jerry wrote:
>ALL, you may have seen several posts last week
>
>about leaky windshield seals on Vanagon's. I finally
>
>fixed mine so I'll relay to listeners what my problem was.
>
>It wasn't the antenna seal, I did install a new antenna
>
>but I new I had an effective seal there.
>
>I thought I had my problem leak fixed until I drove my
>
>Vanagon the same day.  I parked the vehicle for a while
>
>while it was still raining and when I returned there was
>
>rainwater standing in my rubber floormats on both sides.
>
>I waited for another warm day(60 degrees) and parked
>
>the Vanagon facing the bright sunshine.  Previously I
>
>used silicone sealant on the lower corners of the windshield
>
>extending the sealant coverage toward the middle of the windshield.
>
>I pried the seal away from the body channel with a butter knife
>
>and squirted a good bead of sealant between the seal and the
>
>windshield channel.
>
>I didn't put any sealant at the top corners extending down
>
>toward the lower corners on each side. Seems the rain water
>
>was leaking in at the top corners of the windshield seal and
>
>running down the seal channel to the inside of the vehicle.
>
>Drove me nuts for a while.
>
>BOTTOM LINE:  Be sure to seal the entire circumference
>
>of the windshield between the seal and the frame seal channel.
>
>I think mine is finally sealed, I'll know in the morning!
>
>
>
>Jerry
>
>KY 88 GL BUS-ter