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Discussion Starter #1
If you haven't inspected this yet, please have a look at the upper (outer) door seal attachment rib rail.

This metal strip attaches along the roof-line inside the door jamb to which the upper outer weatherstrip attaches.

It is put on with screws in the body build phase and is then painted over with body color.

It is also foam sealed in place to guard against water intrusion but this process now looks weak/flawed because I found the pictured rust.

This rust will extend upwards under the roof rack.

If you do not catch it and repair, you will get roof leaks !

Fortunately i caught mine in time.
 

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Discussion Starter #4
its a creeping crud - bad design

the 5 foot piece of metal that holds the outer weatherstrip is screwed to the roof and sealed with body sealer then painted with final body color.

It appears that either some vibration causes metal-metal rubbing exposing metal, or the body sealer held water and caused the start of it.

Had to remove the metal strip, clean out all the body sealer with a rotating drill mounted brillo wheel - dont use metal - also on the roof side, then prepped the area with permatex rust treatment RT-8a, then start to build up the sealing and painting on both surfaces, then reassemble.

last step, hit it with paint many times.

fortunately, this area is covered by the door when its closed so you cant see the damage or my sloppy paint.

WFH - it wont last forever - lesson learned - - get a southwest car next time and xfer all my good parts onto it.
 

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Chaaz01 speaks truth! Listen to him!

AND! Absolutely investigate this if you are having crazy leaks at your A-pillars! I had a longstanding issue with my XK where it sat idle for about 8 months. The drain tubes clogged, and that led to the sun roof trough holding water. All this moisture rusted the brackets that hold the sun roof, which had to be replaced as it just fell apart when I got the engine replaced and started driving the car again. All that rust managed to get into the drain tubes and clog it up even more, I was having to run a weed whacker line through them every couple of months. I was beginning to suspect the drain tubes might have been broken or dislodged to have so much leaking going on, and I had been planning to replace them with new hoses. I investigated it more when preparing to install a new tv monitor to the ceiling, and found just this issue beginning with my XK. There were MANY, MANY gaps along that metal bar, it honestly looked like no sealant had ever been used. I just got some 3M weather stripping sealant from the auto shop and ran over it twice, did the trick.

EVERYBODY CHECK FOR THIS ON YOUR XK. BOTH SIDES.
 

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Big Blue... everytime you reply I get jealous of your rig. That is almost exactly what I want to do with mine... =)
Thanks @brattrw; I appreciate it.

Keep me posted with your progress.

You could start with some "Before" pics.
 
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