Thanks! Looking forward to getting your conclusion if this works. I have the same situation with my cowl seal. It is "wavy" and does not seal very well.

 

VICTORY!!!

No leaks under the harshest testing.

I think it’s a combination of a larger flap seal around the fan inlet and a better seal between the windshield and cowl.

Done!

 

Thanks again to Tony Luna! Just replaced the broken cowl and also put in the new rubber seal that Tony recommeded. Definitely a much better waterproofing seal.

P/S. I straightened out the wavy kinks after the pic was taken

 

FYI I'm pretty sure I got an edge seal much like the one above from McMaster before. I'll see if I can track it down and get some part numbers later. It makes a lot of sense to use something like that. I was looking at the lower windshield edge seal thinking there's no way I'm getting that to seal without some polyurethane sealant. Reminds me of a similar design on my wife's old X3 that would also pour water onto the floor.
I just assumed European cars all smelled like wet dogs!?! Still smells better than when I got my tundra and it smelled like old french fries and spilled soda. Some people.

 

Anyone try to cover up the air inlet hole with some sort of screen? That's where all the leaves and junk get in and make your blower clogged up and off balance.

 

And don't forget to clean out the drain holes at the fenders. Both of mine were clogged with leaves and acorns and caused the water to fill up and then spill through the fresh air intake which thrilled my wife to no end...

 

Wait! What drain holes in the fenders? This seems like a key detail that might help me out with my own inherent dampness.

 

yes just tucked under the side close to the were the electric cables go through for the heated screen, part of my problem was a rust hole just under the corner of the windscreen but the sealing grommet for the cable was old a loose, so it was letting a lot of water into the foot well