Td5 D2 bodywork - Heater Blower Hole (3)

More research into how and where the rainwater gets access to the blower motor..

Following up on the idea that rainwater can overflow the scuttle and back-drain through the pollen /scuttle filter. It seems that the water does not need to physically enter the blower motors open intake, but can surge around the intake mounting bolts on the bulkhead and if the sealing is not secure,  the water can get access to the blower motor casing that way. 

The inlet is secured to the bulkhead by 5 bolts.

To get the above view, the plastic plenum/scuttle panel must be removed.  Also in this photo can be seen the rusty looking residue of a water drain channel below the inlet. It can be seen to pass close to the bottom-left bolt, and is a potential leak point if that joint is not secure.

Yesterday, I had a go on Hx with the Borro-scope and took these photos of two of the five mounting bolts.

Unfortunately, I did not record where these bolts were on the intake mounting, but a careful study and comparison with the leading photo leads me to believe they are the lower two bolts. (to orientate with the leading photo, the first photo here needs to be turned 90° to the left and the second photo 180°)

More importantly, the obvious difference in their condition surely points to the presence of corrosion in the second photo. There is probably running water passing around that bolt..

The condition of the sealing gasket between the bulkhead and the intake body can be readily compared.. that rusty one looks to be in a bad condition.

Think I need to get the Borro-scope out again and systematically get photos of all the bolts and the gasket seal. There must be more evidence to uncover now that I know what to look for.

It has already occurred to me to apply mastic sealer all around this joint and I did try to practise getting my fingers on the real awkward area. 

The fabrication of some kind of cover for the intake would also require some kind of sealant to be applied. 

I have not progressed the fabrication of a cover for the intake beyond the 'vac-form' plan. I figure it needs to be fabricated from thin plate to be flexible enough.

Here is a photo looking down the blower intake assembly. The 'hamster wheel' of the blower motor can be seen. I am not sure how the intake cowl mounts on top of this...