Re: Update: found the leak :-( - Saab 9-5 Bulletin Board - Saabnet.com
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Re: Update: found the leak :-(
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Posted by Snowmobile [Email] (#686) [Profile/Gallery] (more from Snowmobile) on Sun, 7 Jul 2024 04:39:44 Share Post by Email
In Reply to: Re: Update: found the leak :-(, Paul from Palmyra, PA, Fri, 5 Jul 2024 14:22:46
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Thanks. I've used a lot of por15 and it is great stuff. I have the filler and it dries rock hard, super hard to sand. Another por15 trick I have used is you can soak fiberglass cloth in it and it dries hard like steel. Works better than polyester resin imho for small holes.

So I have considered that as an option. The downsides: 1) it lasts better than other paint but rust does come back in our climate. 2-3 years vs 6 months for other products. 2) it requires a week of perfect dry sunny hot but not too hot conditions to go through all the steps. Any moisture affects the longevity. 3) I don't know if it is necessary that the firewall be all metal. Afaik a hole to the cabin would fail safety in some places (if you look closely at my photo, you can see the foam from the fender).

However, it would be better than tearing out the whole dash and I only expect to get another 2-3 years out of it. It's a family hauler not a show car (also have c900s).

In terms of "is this normal?" I would say that, yes the top of the drains did get clogged a lot with leaves, but they don't get down where the rust is. It is possible that a clogged drain might allow less water into that area over time, or it might just continuously trickle and never dry out. Hard to say which. But I think 20 winters of salt water washing down into an untreated seam (it has a wax seal, but if the seal fails it will just collect more moisture) is going to cause trouble. Really, the drains should have a more direct route and through some sort of hose that keeps water away from steel. Of course nowadays, especially with a priority on leasing, that level of longevity from rust wouldn't be a consideration...


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