Cowl Leaks

[Kisner]

I had the same identical problem with my 68. The first time I washed it after I restored it, water came pouring in from the right-hand pillar and also under the dash on the right-hand side. I also used the garden hose in the cowl and not a drop leaked. Turned out to be leaking from the top right-hand corner of the windshield and was running down the pillar to behind the dash. After I removed the windshield moulding, I could see a very small opening at the top right-hand corner of the windshield gasket. Figured out the brand new gasket wasn't made perfectly flush at that corner and had a slight bulge in it creating an opening. I taped off the windshield area with blue masking tape so I wouldn't have a massive cleanup, and "gobbed" as much of the black gooey windshield sealant in that area, and the entire windshield area again, as I could, waited a few days for it to set up, tested it with a continuous flow of water from the hose for a good 15 minutes (before I put the moulding back on), and all my problems were solved. After later talking with several people with windshield experience, I found out you can't go by the shop manual which says to use a 1/4" inch bead of sealant - you have to gob it on as much as you can without extruding beyond the moulding to stop those pesky leaks. So, I would bet money it's your windshield and another "real good" bead of sealant will stop it. Also, put a bead between the glass and gasket to ensure you don't have leaks from that direction either.