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I think I might finally have this under control. I was very discouraged there for a while, but it seems to be sealed up properly now.
I am going to recommend against drilling through that plug/cap if at all possible. If you can get the power through without removing/drilling then do it. It was not possible in my case as the plastic plug broke off...
I went through two sticks of the permatex mash-together epoxy repair stuff.
Here's my advice for using this stuff:
- clean your hands well. Any dirt/grease/etc on your hands will quickly contaminate the material and make it not mix as well and not be as sticky.
- clean your work. Same thing as with your hands - any dirt etc will get into this stuff quickly.
- it's not very sticky to begin with so be sure to really mash it in to the places you need it to go so that it contacts all surfaces properly.. But don't mash it too thin or it won't seal anything either.
- don't work it too long - it starts to harden after a couple of minutes, and it turns crusty and flaky. You want it all applied before this happens.
- use lots of it. Don't be afraid to buy two sticks. I mixed in little batches of about 1/2 inch pieces of the stick so I could get it applied before it started to set up.
- I think the liquid stuff worked better around the wires than the past/stick stuff. In general I think the liquid stuff was better, but you have to apply it REALLY fast, as it clumps up quickly. And it gets REALLY hot, so either wear a glove with the hand holding the pouch or find some way to hold it close without coming into close contact with your skin. Man this stuff gets hot!
If this holds up until tomorrow I'll button the whole thing up.
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1998 V70 AWD Turbo 195k+
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