No leaks on the roof. None on the side windows. This speaks highly of how well built and sealed the bodies of these machines were. Most leaks were in the area where the floor butts up against the outer skin. The rotting floor had, over years of constant humidity, corroded the outer aluminum skin creating pinholes along the lower sides and upper belly.
Several anodized aluminum patches with Olympic rivets were installed on the outside. Each rivet was sealed with TremPro polyurethane sealant. Each panel was sealed to the skin with gutterseal. The pinholes were additionally sealed from the inside with Parrbond.
Some of the belly patches. These are just below the baggage compartment area on the driver side of the trailer. You can see I have not yet "shaved" the Olympic rivets:
The front window had two small leaks at either end where all the curved front panels meet right above the window frame. Just like the rear window, same poor design.
Pulled the rock guard and the window when we had a dry spell (2 days in early February). 30 degree weather is not the ideal time for window repair but if I waited for warmer weather we could be talking weeks and I wanted to get the leaks under control so I could put the floor back in. I doubled up on the butyl tape to ensure enough thickness to seal the window against the seam joints. Applied gutterseal to the joint as well. When I was done I could see from the inside that there were a few drops weeping in between the butyl tape and the skin, right below where all the seams meet...Aaarrrggg!...
It took 100 degree weather, which we had in May (record highs) to finally make the weeping stop. I am talking about the window weeping, as well as mine...
All this working in the rain for weeks at least insured that I got all the leaks taken care of! If I had been working indoors I never would have found all the tiny pinhole leaks. You would be surprised how much water can come in during a 24 hour period of Pacific Northwest winter weather through a tiny hole. Now she will be nice and dry going forward.