SOLVED: Floor board leak...Roof channel issue leaks
 

I just got a 2018 SR5 Premium a few months ago and it had the roof rack removed and the replacement kit installed. I found a local roof rack and installed it, sealing it properly, etc.

After a hard rain the other day, I found water on my driver's side floorboard. Drove me crazy with trying to find out where it was coming from as I have a sunroof, but surely the drain holes were not plugged as it's only two years old. I finally pulled up the roof channel strips on both sides and there's a threaded hole there about 10 inches back from the windshield, in the channel, for no main purpose that I can see. The rubber channels were being held down with double-sided tape, which I have now removed.

Anyway underneath the strips was a fair amount of rust forming and this vehicle came from Arizona. I got rid of the rust pretty easily as Evapo-Rust is pretty badass, but I don't know how many of you are driving around with that issue. I found an older post about this in the forums and lot of folks are gluing them down as they tend to come off in the car washes. I plan to go this route myself.

This is a bad design, I think, and am going to plug the two holes with Sugru unless anyone has a better idea. Screw in plugs would be ideal but I don't plan to ever use those front holes for anything.

This is why you shouldn't mess with the roof rack if you don't have to. Many people developed leaks after messing with their roof rack and disturbing the factory sealant.

do you have pics of this problem?