CheeseHelmet
Member
Forgot to update this thread...
I finally fixed the leak last weekend, I had to remove the dash, the A/C evaporator, and finally the blower motor assembly. It was an annoying job but I was able to do it in a garage so at least I didn't have to deal with the wind/rain/cold/etc.
The hole was right where I felt the rust patch last time, right along a welded seam, it appears Mazda simply didn't put enough weld sealer and the rust made it through. The hole was approximately 4cm long and a little under a centimeter wide. I ended up just filling it with some black RTV; I tested it 24 hours later and it no longer leaked. I've been driving around for a week in pretty bad weather with a nice dry passenger floor.
I finally fixed the leak last weekend, I had to remove the dash, the A/C evaporator, and finally the blower motor assembly. It was an annoying job but I was able to do it in a garage so at least I didn't have to deal with the wind/rain/cold/etc.
The hole was right where I felt the rust patch last time, right along a welded seam, it appears Mazda simply didn't put enough weld sealer and the rust made it through. The hole was approximately 4cm long and a little under a centimeter wide. I ended up just filling it with some black RTV; I tested it 24 hours later and it no longer leaked. I've been driving around for a week in pretty bad weather with a nice dry passenger floor.