Update time!
Given that Eric lives in Canada and the XJ and I live in the US, shortly after the last update it became impossible for him to come visit. The Jeep spent most of the summer parked with the battery disconnected, with just the occasional run to the recycling depot or the home depot when I needed some cargo space but didn't feel like awakening the Big Diesel.
But I've been going a little stir crazy and needed to clear my head from what's going on at work, so I decided to hit the mountains.
But first, some work. This has been a long time coming. There's a leak in the passenger's footwell. Given that we've had a grand total of 3" of precipitation so far this year, the rubber mats are able to catch and hold it so it's not high priority. But it's high enough.
The problem is the HVAC intake in the sill. It's sealed with some sort of foam that breaks down over time and allows water to get in. There's no easy access. So it's grinder time. Luckily, this is hidden under a fake grill.
After that was done, it was a matter of drilling out a couple of spot welds to remove the flange at the top of the HVAC inlet. It's about an inch tall to provide a dam if the sill fills with water. Here's what was sealing the flange at the bottom.
I cleaned up all surfaces as best I could, flattened the flange out and then proceeded to go to town with silicone sealant. No pictures, that's messy work. Let's just say that there should be no more leakage around the bottom of that flange.
I then tack-welded the piece of sheetmetal back into place and went back to town with RTV to seal it up. It's not critical that it be weatherproof as there are other paths for the water to get into the sill, but it seemed like a good idea. This picture also gives you an idea of the location of the fix.
A bit of masking and a coat of Rustoleum. It may not stick to the RTV, but the RTV doesn't need rust protection.
I did not have a hose handy to test it, maybe I'll give it a shot this weekend. But based on what I pulled out, it should be effective. With the plastic grille back on, the repair is invisible.